International Engines models N9, N10 Diagnostics/Troubleshooting/Repair/Operation & Maintenance Manuals
Complete service repair manual with Electrical Wiring Diagrams for International series N9, N10 Diesel Engines, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
International / Navistar Diesel Engines N9, N10 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 5,681 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
0000002861 - 2013 HD-OBD Diagnostic Reference Manual.pdf
0000002861 - Service Manual 2013 HD-OBD Diagnostic Reference Manual.pdf
0000003481-R2 - N9 and N10 with SCR Engine Wiring Diagram.pdf
0000003721 (082015) - N9 and N10 Engine Diagnostics Manual.pdf
0000003721 (122014) - N9 and N10 Engine Diagnostics Manual.pdf
0000004021 - N9 and N10 Engine Service Manual.pdf
4328224R1 - N9 and N10 Engine Operation and Maintenance Manual.pdf
MAIN SECTIONS
0000002861 - 2013 HD-OBD Diagnostic Reference Manual....1
toc....3
Table of Contents....3
Foreword....5
Safety information....6
Safety Terminology....6
Safety Instructions....6
Work Area....6
Safety Equipment....6
Protective Measures....6
Vehicle....7
Engine....7
Fire Prevention....7
Batteries....7
Compressed Air....7
Tools....8
Fluids Under Pressure....8
Fuel....8
Removal of Tools, Parts, and Equipment....8
On Board Diagnostics (OBD) Overview....9
Diagnostic Trouble Code overview....10
Warranty information....11
5.1. Drive cycles....11
Road Testing is not covered by warranty, see the CTS-1100 Warranty and Procedure Manual for more Information...11
drive cycles....12
6.1. MaxxForce? 11 and 13 (EPA 10) with HD-OBD....12
6.2. N13 with SCR (EPA 10) with HD-OBD....13
Failure Mode Indicator (FMI) Hierarchy....15
Definitions / Acronyms....16
0000002861 - Service Manual 2013 HD-OBD Diagnostic Reference Manual....17
toc....19
Table of Contents....19
Foreword....21
Safety information....22
Safety Terminology....22
Safety Instructions....22
Work Area....22
Safety Equipment....22
Protective Measures....22
Vehicle....23
Engine....23
Fire Prevention....23
Batteries....23
Compressed Air....23
Tools....24
Fluids Under Pressure....24
Fuel....24
Removal of Tools, Parts, and Equipment....24
On Board Diagnostics (OBD) Overview....25
Diagnostic Trouble Code overview....26
Warranty information....27
5.1. Drive cycles....27
Road Testing is not covered by warranty, see the CTS-1100 Warranty and Procedure Manual for more Information...27
drive cycles....28
6.1. MaxxForce? 11 and 13 (EPA 10) with HD-OBD....28
6.2. N13 with SCR (EPA 10) with HD-OBD....29
Failure Mode Indicator (FMI) Hierarchy....31
Definitions / Acronyms....32
0000003481-R2 - N9 and N10 with SCR Engine Wiring Diagram....33
0000301101....33
0000300403....34
0000159985....35
0000003721 (08?2015) - N9 and N10 Engine Diagnostic Manual....36
toc....38
Table of Contents....38
Safety Terminology....42
Safety Instructions....42
Work Area....42
Safety Equipment....42
Protective Measures....42
Vehicle....42
Engine....43
Fire Prevention....43
Batteries....43
Compressed Air....43
Tools....43
Fluids Under Pressure....44
Fuel....44
Removal of Tools, Parts, and Equipment....44
Table of Contents....46
Diagnostic Trouble Code (DTCs) List....50
How To Use Symptom Based Diagnostics....63
Operational Checkout Procedures....64
1.0 - Preliminary Vehicle Operational Checkout Procedure....64
2.0 - Engine Does Not Start Operational Checkout Procedure....67
Overview....67
3.0 - Engine Hard to Start Operational Checkout Procedure....71
Overview....71
4.0 - Engine Running, Engine Not Under Load Operational Checkout Procedure....75
Overview....75
5.0 - Engine Running, Engine Under Load Operational Checkout Procedure....77
Overview....77
6.0 - Cooling System Operational Checkout Procedure....79
Overview....79
7.0 - Engine Oil System Operational Checkout Procedure....82
Overview....82
8.0 - Fuel System Operational Checkout Procedure....84
9.0 - Engine Compression Brake Operational Checkout Procedure....85
10.0 - SCR Aftertreatment Operational Checkout Procedure....86
Overview....86
Test Procedure....86
11.0 - ECM Loss of Communication....87
Overview....87
Possible Causes....87
Test Procedure....87
12.0 Soot Buildup at Exhaust Manifold / Gasket Out of Position....94
Overview....94
Possible Causes....94
Test Procedure....94
Engine Does Not Start Symptoms....98
2.1 - Engine Cranks Slow or Does Not Crank....98
Overview....98
Possible Causes....98
Test Procedure....98
2.2 - Engine No Start, Cold Ambient Temperature....101
Overview....101
Possible Causes....101
Test Procedure....101
2.3 - Engine at Operating Temperature, No Re-Start....103
Overview....103
Possible Causes....103
Test Procedure....103
2.4 - Engine Never Starts....105
Overview....105
Possible Causes....105
Test Procedure....105
Engine Hard to Start Symptoms....108
3.1 - Engine Hard to Start, Cold Ambient Temperature....108
Overview....108
Possible Causes....108
Test Procedure....108
3.2 - Engine at Operating Temperature, Hard to Re-Start....110
Overview....110
Possible Causes....110
Test Procedure....110
3.3 - Engine Starts, Then Stalls....112
Overview....112
Possible Causes....112
Test Procedure....112
Engine Running, Engine Not Under Load Symptoms....114
4.1 - Rough Idle....114
Overview....114
Possible Causes....114
Test Procedure....114
4.2 - Engine Unable To Reach Rated Speed (No Load)....118
Overview....118
Possible Causes....118
Test Procedure....118
4.3 - Popping Noise from Intake....121
Overview....121
Possible Causes....121
Test Procedure....121
Engine Running, Engine Under Load Symptoms....123
5.1 - Low Power (Slow Acceleration)....123
Overview....123
Possible Causes....123
Test Procedure....123
5.2 - Misfire (Stumble / Surge / Runs Rough)....129
Overview....129
Possible Causes....129
Test Procedure....129
5.3 - Engine Unable to Reach Desired Speed During PTO Operation....132
Overview....132
Possible Causes....132
Test Procedure....132
Engine Coolant Symptoms....135
6.1 - Coolant Overflow....135
Overview....135
Possible Causes....135
Test Procedure....135
6.2 - Coolant Over Temperature....138
Overview....138
Possible Causes....138
Test Procedure....138
6.3 - Engine Unable to Reach Operating Temperature....141
Overview....141
Possible Causes....141
Test Procedure....141
6.4 - Coolant Leak to Exhaust....143
Overview....143
Possible Causes....143
Test Procedure....143
6.5 - Coolant Leak to Intake....145
Overview....145
Possible Causes....145
Test Procedure....145
6.6 - Coolant Leak to Engine Oil ....146
Overview....146
Possible Causes....146
Test Procedure....146
Engine Lubrication Symptoms....147
7.1 - Engine Oil Contamination....147
Overview....147
Possible Causes....147
Test Procedure....147
7.2 - Engine Oil Leak to Intake....150
Overview....150
Possible Causes....150
Test Procedure....150
7.3 - Engine Oil Leak to Exhaust....152
Overview....152
Possible Causes....152
Test Procedure....152
7.4 - Low Engine Oil Pressure....153
Overview....153
Possible Causes....153
Test Procedure....153
7.5 - High Engine Oil Pressure....156
Overview....156
Possible Causes....156
Test Procedure....156
7.6 - Engine Oil Aeration....158
Overview....158
Possible Causes....158
Test Procedure....158
Fuel System Symptoms....160
8.1 - Fuel Delivery Pressure....160
Overview....160
Possible Causes....160
Test Procedure....160
8.2 - Fuel in Engine Oil....164
Overview....164
Possible Causes....164
Test Procedure....164
Engine Brake Symptoms....167
9.1 - Engine Compression Brake Inoperative....167
Overview....167
Possible Causes....167
Test Procedure....167
9.2 - Engine Compression Brake Engaged When Not Commanded ....170
Overview....170
Possible Causes....170
Test Procedure....170
Aftertreatment Symptoms....172
10.1 - Parked Regeneration Will Not Activate....172
Overview....172
Possible Causes....172
Test Procedure....172
10.2 - Black Smoke ....174
Overview....174
Possible Causes....174
Test Procedure....174
10.3 - White Smoke....179
Overview....179
Possible Causes....179
Test Procedure....179
Fault Code Diagnostics....184
Section Information....184
AAT Sensor (Ambient Air Temperature)....185
Overview of AAT Sensor....185
Overview ....185
SPN 171 FMI 2 - AAT Signal Erratic, Intermittent, or Incorrect....186
Fault Overview....186
Lamp Reaction....186
Associated Faults....186
Fault Facts....186
Drive Cycle to Determine Fault Status....186
Possible Causes....186
Pin-Point Test....190
Tools Required....190
SPN 171 FMI 3 - AAT Signal Out of Range HIGH....194
Fault Overview....194
Lamp Reaction....194
Associated Faults....194
Fault Facts....194
Drive Cycle....194
Possible Causes....194
Pin-Point Test....197
Tools Required....197
SPN 171 FMI 4 - AAT Signal Out of Range LOW....201
Fault Overview....201
Lamp Reaction....201
Associated Faults....201
Fault Facts....201
Drive Cycle to Determine Fault Status....201
Possible Causes....201
Pin-Point Tests (SPN 171 FMI 4)....203
Tools Required....203
ACM (Aftertreatment Control Module)....205
Overview of ACM Sensor....205
Overview ....205
SPN 168 FMI 15 - ACM Battery voltage too HIGH....206
Fault Overview....206
Lamp Reaction....206
Associated Faults....206
Fault Facts....206
Drive Cycle to Determine Fault Status....206
Possible Causes....206
SPN 168 FMI 17 - ACM Battery voltage too LOW....208
Fault Overview....208
Lamp Reaction....208
Associated Faults....208
Fault Facts....208
Drive Cycle to Determine Fault Status....208
Possible Causes....208
Pin-Point Tests (SPN 168 FMI 17)....210
Tools Required....210
AFT (Aftertreatment) System....212
Overview of AFT System Group....212
Overview....212
SPN 3251 FMI 0 - DPFDP excessively HIGH (Plugged filter)....214
Fault Overview....214
Lamp Reaction....214
Associated Faults....214
Fault Facts....214
Drive Cycle to Determine Fault Status....214
Possible Causes....214
Pin-Point Tests....218
Tools Required....218
SPN 3251 FMI 15 - DPF Soot Load - Least Severe Level....219
Fault Overview....219
Lamp Reaction....219
Associated Faults....219
Fault Facts....219
Drive Cycle to Determine Fault Status....219
Possible Causes....219
Pin-Point Tests....223
Tools Required....223
SPN 3251 FMI 16 - DPF Soot Load - Moderately Severe Level....224
Fault Overview....224
Lamp Reaction....224
Associated Faults....224
Fault Facts....224
Drive Cycle to Determine Fault Status....224
Possible Causes....224
Pin-Point Tests....228
Tools Required....228
SPN 3695 FMI 2- DPF Regen Inhibit Switch erratic, intermittent, or incorrect....229
Fault Overview....229
Lamp Reaction....229
Associated Faults....229
Fault Facts....229
Drive Cycle to Determine Fault Status....229
Possible Causes....229
SPN 3695 FMI 19 - DPF Regen Inhibit Switch status not detected on J1939 ....231
Fault Overview....231
Lamp Reaction....231
Associated Faults....231
Fault Facts....231
Drive Cycle to Determine Fault Status....231
Possible Causes....231
SPN 3703 FMI 31 - DPF Active Regeneration Inhibited Due to Inhibit Switch....233
Fault Overview....233
Lamp Reaction....233
Associated Faults....233
Fault Facts....233
Drive Cycle to Determine Fault Status....233
Possible Causes....233
SPN 3713 FMI 31 - DPF Active Regeneration Inhibited Due to System Timeout....235
Fault Overview....235
Lamp Reaction....235
Associated Faults....235
Drive Cycle to Determine Fault Status....235
Fault Fact....235
Possible Causes....235
SPN 3719 FMI 0: DPF Soot Load - Highest (level 3/3)....237
Fault Overview....237
Lamp Reaction....237
Associated Faults....237
Fault Facts....237
Drive Cycle to Determine Fault Status....237
Possible Causes....237
SPN 3719 FMI 15 DPF Soot Load - Lowest (level 1/3)....240
Fault Overview....240
Lamp Reaction....240
Associated Faults....240
Fault Facts....240
Drive Cycle to Determine Fault Status....240
Possible Causes....240
SPN 3719 FMI 16 - DPF Soot Load - Moderate (level 2/3)....243
Fault Overview....243
Lamp Reaction....243
Associated Faults....243
Fault Facts....243
Drive Cycle to Determine Fault Status....243
Possible Causes....243
SPN 3750 FMI 31 - DPF Regen inhibited due to low exhaust temperatures ....246
Fault Overview....246
Lamp Reaction....246
Associated Faults....246
Fault Facts....246
Drive Cycle to Determine Fault Status....246
Possible Causes....246
SPN 3936 FMI 14 - DOC / DPF Temperature module (Incorrect Part)....248
Fault Overview....248
Lamp Reaction....248
Associated Faults....248
Fault Facts....248
Drive Cycle to Determine Fault Status....248
Possible Causes....248
SPN 3936 FMI 15 - DPF System above Warning Pressure....250
Fault Overview....250
Lamp Reaction....250
Associated Faults....250
Fault Facts....250
Drive Cycle to Determine Fault Status....250
Possible Causes....250
SPN 3936 FMI 16 - DPF System above Maximum Pressure....254
Fault Overview....254
Lamp Reaction....254
Associated Faults....254
Fault Facts....254
Drive Cycle to Determine Fault Status....254
Possible Causes....254
SPN 4795 FMI 31 - DPFDP Excessively LOW (Sensor/Circuit Fault or Missing DPF)....258
Fault Overview....258
Lamp Reaction....258
Associated Faults....258
Fault Facts....258
Drive Cycle to Determine Fault Status....258
Possible Causes....258
SPN 4796 FMI 31 - Diesel Oxidation Catalyst Missing....260
Fault Overview....260
Lamp Reaction....260
Associated Faults....260
Fault Facts....260
Drive Cycle to Determine Fault Status....260
Possible Causes....260
SPN 5298 FMI 17 - DOC Efficiency fault, Temperature below minimum Regen Aborted....262
Fault Overview....262
Lamp Reaction....262
Associated Faults....262
Fault Facts....262
Drive Cycle to Determine Fault Status....262
Possible Causes....262
SPN 5298 FMI 18 - DOC Efficiency fault, Temperature below minimum....265
Fault Overview....265
Lamp Reaction....265
Associated Faults....265
Fault Facts....265
Drive Cycle to Determine Fault Status....265
Possible Causes....265
SPN 5319 FMI 31 - DPF incomplete Regeneration....267
Fault Overview....267
Lamp Reaction....267
Associated Faults....267
Fault Facts....267
Drive Cycle to Determine Fault Status....267
Possible Causes....267
AFTFSO (Aftertreatment Fuel Shutoff)....270
Overview of AFTFSO Sensor Group....270
Overview....270
SPN 3482 FMI 3 - AFT Fuel Enable Control Valve short to PWR....271
Fault Overview....271
Lamp Reaction....271
Associated Faults....271
Fault Facts....271
Drive Cycle to Determine Fault Status....271
Possible Causes....271
Pin-Point Tests....276
Tools Required....276
SPN 3482 FMI 4 - AFT Fuel Shutoff Valve open or short to GND....282
Fault Overview....282
Lamp Reaction....282
Associated Faults....282
Fault Facts....282
Drive Cycle to Determine Fault Status....282
Possible Causes....282
Pin-Point Tests....287
Tools Required....287
AFTFP1/AFTFT (Aftertreatment Fuel Pressure 1 / Aftertreatment Fuel Temperature) Sensor....293
Overview of AFTFP1/AFTFT Sensor Group....293
Overview....293
SPN 3480 FMI 3 - AFTFP1 signal Out of Range HIGH....295
Fault Overview....295
Lamp Reaction....295
Associated Faults....295
Fault Facts....295
Drive Cycle to Determine Fault Status....295
Possible Causes....295
Pin-Point Tests....298
Tools Required....298
SPN 3480 FMI 4 - AFTFP1 signal Out of Range LOW....302
Fault Overview....302
Lamp Reaction....302
Associated Faults....302
Fault Facts....302
Drive Cycle to Determine Fault Status....302
Possible Causes....302
Pin-Point Tests....305
Tools Required....305
SPN 5456 FMI 2 - AFTFT Signal Erratic, Intermittent, or Incorrect....309
Fault Overview....309
Lamp Reaction....309
Associated Faults....309
Fault Facts....309
Drive Cycle....309
Possible Causes....309
Pin - Point Tests....312
Tools Required....312
SPN 5456 FMI 3 - AFTFT Signal Out of Range - HIGH....314
Fault Overview....314
Lamp Reaction....314
Associated Faults....314
Fault Facts....314
Drive Cycle to Determine Fault Status....314
Possible Causes....314
Pin-Point Tests....317
Tools Required....317
SPN 5456 FMI 4 - AFTFT Signal Out of Range LOW....320
Fault Overview....320
Lamp Reaction....320
Associated Faults....320
Fault Facts....320
Drive Cycle to Determine Fault Status....320
Possible Causes....320
Pin-Point Tests....322
Tools Required....322
AFTFP2 (Aftertreatment Fuel Pressure 2) Sensor....323
Overview of AFTFP2 Sensor Group....323
Overview....323
SPN 3556 FMI 0 - AFT Fuel Pressure 2 excessively high (Restricted injection)....324
Fault Overview....324
Lamp Reaction....324
Associated Faults....324
Fault Facts....324
Drive Cycle to Determine Fault Status....324
Possible Causes....324
SPN 3556 FMI 1 - AFT Fuel Pressure 2 below desired (Possible system leak)....326
Fault Overview....326
Lamp Reaction....326
Associated Faults....326
Fault Facts....326
Drive Cycle to Determine Fault Status....326
Possible Causes....326
Pin-Point Tests....329
Tools Required....329
SPN 3556 FMI 7 - AFT Fuel Injector not responding as expected....330
Fault Overview....330
Lamp Reaction....330
Associated Faults....330
Fault Facts....330
Drive Cycle to Determine Fault Status....330
Possible Causes....330
SPN 4077 FMI 3 - AFTFP2 Signal Out of Range HIGH....332
Fault Overview....332
Lamp Reaction....332
Associated Faults....332
Fault Facts....332
Drive Cycle to Determine Fault Status....332
Possible Causes....332
Pin-Point Tests....335
Tools Required....335
SPN 4077 FMI 4 - AFTFP2 Signal Out of Range LOW....338
Fault Overview....338
Lamp Reaction....338
Associated Faults....338
Fault Facts....338
Drive Cycle to Determine Fault Status....338
Possible Causes....338
Pin-Point Tests....340
Tools Required....340
AFTFPC (Aftertreatment Fuel Pressure Control) System....341
Overview of AFTFPC Sensor....341
Overview....341
SPN 3471 FMI 1 - AFT Fuel Pressure 1 below desired (Low system pressure)....342
Fault Overview....342
Lamp Reaction....342
Associated Faults....342
Fault Facts....342
Drive Cycle to Determine Fault Status....342
Possible Causes....342
Pin-Point Tests....345
Tools Required....345
SPN 3471 FMI 7 - AFT Fuel Doser Valve not responding as expected....348
Fault Overview....348
Lamp Reaction....348
Associated Faults....348
Fault Facts....348
Drive Cycle to Determine Fault Status....348
Possible Causes....348
Pin-Point Tests....351
Tools Required....351
SPN 3471 FMI 10 - AFT Fuel Pressure incorrect dosing pressure multiple events....354
Fault Overview....354
Lamp Reaction....354
Associated Faults....354
Fault Facts....354
Drive Cycle to Determine Fault Status....354
Possible Causes....354
Pin-Point Tests....357
Tools Required....357
SPN 3479 FMI 3 - AFT Fuel Doser Valve Short to PWR....360
Fault Overview....360
Lamp Reaction....360
Associated Faults....360
Fault Facts....360
Drive Cycle to Determine Fault Status....360
Possible Causes....360
Pin-Point Tests....365
Tools Required....365
SPN 3479 FMI 4 - AFT Fuel Doser Valve Short to GND....368
Fault Overview....368
Lamp Reaction....368
Associated Faults....368
Fault Facts....368
Drive Cycle to Determine Fault Status....368
Possible Causes....368
Pin-Point Tests....373
Tools Required....373
SPN 3479 FMI 5 - AFT Fuel Pressure Valve Open or Short to GND low side....376
Fault Overview....376
Lamp Reaction....376
Associated Faults....376
Fault Facts....376
Drive Cycle to Determine Fault Status....376
Possible Causes....376
Pin-Point Tests....381
Tools Required....381
SPN 3479 FMI 6 - AFT Fuel Doser Valve High Side Short circuit....384
Fault Overview....384
Lamp Reaction....384
Associated Faults....384
Fault Facts....384
Drive Cycle to Determine Fault Status....384
Possible Causes....384
Pin-Point Tests....389
Tools Required....389
NH3 (Aftertreatment Ammonia) Sensor and Sensor Module....392
Overview of NH3 Sensor Group....392
Overview....392
SPN 4377 FMI 2 - NH3 in range stuck fault....396
Fault Overview....396
Lamp Reaction....396
Associated Faults....396
Fault Facts....396
Drive Cycle to Determine Fault Status....396
Possible Causes....396
SPN 4377 FMI 3 - NH3 Sensor signal Out of Range HIGH....398
Fault Overview....398
Lamp Reaction....398
Associated Faults....398
Fault Facts....398
Drive Cycle to Determine Fault Status....398
Possible Causes....398
SPN 4377 FMI 4 - NH3 operation fault (circuit fault)....400
Fault Overview....400
Lamp Reaction....400
Associated Faults....400
Fault Facts....400
Drive Cycle to Determine Fault Status....400
Possible Causes....400
SPN 4377 FMI 10 - NH3 abnormal rate of change....402
Fault Overview....402
Lamp Reaction....402
Associated Faults....402
Fault Facts....402
Drive Cycle to Determine Fault Status....402
Possible Causes....402
SPN 4377 FMI 12 - NH3 internal chip error....403
Fault Overview....403
Lamp Reaction....403
Associated Faults....403
Fault Facts....403
Drive Cycle to Determine Fault Status....403
Possible Causes....403
SPN 4377 FMI 13 - NH3 operation fault (wrong sensor installed)....405
Fault Overview....405
Lamp Reaction....405
Associated Faults....405
Fault Facts....405
Drive Cycle to Determine Fault Status....405
Possible Causes....405
SPN 4377 FMI 19 - NH3 Sensor Module not detected on J1939....407
Fault Overview....407
Lamp Reaction....407
Associated Faults....407
Fault Facts....407
Drive Cycle to Determine Fault Status....407
Possible Causes....407
Pin-Point Tests (SPN 4377 FMI 19)....412
Tools Required....412
SPN 4380 FMI 2 - NH3 signal erratic, intermittent, or incorrect....417
Fault Overview....417
Lamp Reaction....417
Associated Faults....417
Fault Facts....417
Drive Cycle to Determine Fault Status....417
Possible Causes....417
Pin-Point Tests (SPN 4380 FMI 2)....420
Tools Required....420
SPN 4382 FMI 10 - NH3 sensor Heater abnormal rate of change....423
Fault Overview....423
Lamp Reaction....423
Associated Faults....423
Fault Facts....423
Drive Cycle to Determine Fault Status....423
Possible Causes....423
SPN 5302 FMI 18 - Post SCR NH3 Conversion Efficiency - Data Valid But Below Normal Operating Range - Moderately Severe Level....425
Fault Overview....425
Lamp Reaction....425
Associated Faults....425
Fault Facts....425
Drive Cycle to Determine Fault Status....425
Possible Causes....425
AMS (Air Management System)....428
Overview of AMS Sensor Group....428
Overview....428
SPN 1209 FMI 0 - EBP above desired level....429
Fault Overview....429
Lamp Reaction....429
Associated Faults....429
Fault Facts....429
Drive Cycle to Determine Fault Status....429
Possible Causes....429
SPN 1209 FMI 7 - EBP signal not responding as expected....432
Fault Overview....432
Lamp Reaction....432
Associated Faults....432
Fault Facts....432
Drive Cycle to Determine Fault Status....432
Possible Causes....432
SPN 2659 FMI 10 - EGR Slow Response Fault....434
Fault Overview....434
Lamp Reaction....434
Associated Faults....434
Fault Facts....434
Drive Cycle to Determine Fault Status....434
Possible Causes....434
SPN 2659 FMI 14 - EGR System Flow Rate Error During Air Management....438
Fault Overview....438
Lamp Reaction....438
Associated Faults....438
Fault Facts....438
Drive Cycle to Determine Fault Status....438
Possible Causes....438
SPN 2659 FMI 20 - EGR High Flow Rate detected....440
Fault Overview....440
Lamp Reaction....440
Associated Faults....440
Fault Facts....440
Drive Cycle to Determine Fault Status....440
Possible Causes....440
SPN 2659 FMI 21- EGR Low Flow Rate detected....443
Fault Overview....443
Lamp Reaction....443
Associated Faults....443
Fault Facts....443
Drive Cycle to Determine Fault Status....443
Possible Causes....443
APP Sensor (Accelerator Pedal Position)....446
Overview of APP Sensor Group....446
Overview....446
SPN 91 FMI 2 APP1 and APP2 signal conflict....447
Fault Overview....447
Lamp Reaction....447
Associated Faults....447
Fault Facts....447
Drive Cycle to Determine Fault Status....447
Possible Causes....447
Pin-Point Tests....450
Tools Required....450
SPN 91 FMI 3 - APP1 signal Out of Range HIGH....452
Fault Overview....452
Lamp Reaction....452
Associated Faults....452
Fault Facts....452
Drive Cycle to Determine Fault Status....452
Possible Causes....452
Pin-Point Tests (SPN 91 FMI 3)....455
Tools Required....455
SPN 91 FMI 4 - APP1 signal Out of Range LOW....457
Fault Overview....457
Lamp Reaction....457
Associated Faults....457
Fault Facts....457
Drive Cycle to Determine Fault Status....457
Possible Causes....457
Pin-Point Tests (SPN 91 FMI 4)....460
Tools Required....460
SPN 2623 FMI 3 - APP2 Signal Out of Range HIGH....464
Fault Overview....464
Lamp Reaction....464
Associated Faults....464
Fault Facts....464
Drive Cycle to Determine Fault Status....464
Possible Causes....464
Pin-Point Tests (SPN 2623 FMI 3)....467
Tools Required....467
SPN 2623 FMI 4 - APP2 Signal Out of Range LOW....469
Fault Overview....469
Lamp Reaction....469
Associated Faults....469
Fault Facts....469
Drive Cycle to Determine Fault Status....469
Possible Causes....469
Pin-Point Tests (SPN 2623 FMI 4)....472
Tools Required....472
Body....476
Overview of Body Sensor....476
Overview....476
SPN 521 FMI 2 - Brake applied while APP applied....477
Fault Overview....477
Lamp Reaction....477
Associated Faults....477
Fault Facts....477
Drive Cycle to Determine Fault Status....477
Possible Causes....477
SPN 596 FMI 19 Cruise Control Enable Switch not detected on J1939....480
Fault Overview....480
Lamp Reaction....480
Associated Faults....480
Fault Facts....480
Drive Cycle to Determine Fault Status....480
Possible Causes....480
SPN 597 FMI 2 - Missing J1939 Brake status signal request from Body module or Instrument Cluster....482
Fault Overview....482
Lamp Reaction....482
Associated Faults....482
Fault Facts....482
Drive Cycle to Determine Fault Status....482
Possible Causes....482
SPN 597 FMI 19 - Brake switch not detected on J1939....484
Fault Overview....484
Lamp Reaction....484
Associated Faults....484
Fault Facts....484
Drive Cycle to Determine Fault Status....484
Possible Causes....484
CACOT Sensor (Charge Air Cooler Outlet Temperature)....486
Overview of CACOT Sensor Group....486
Overview....486
SPN 2630 FMI 2 - CACOT signal erratic, intermittent, or incorrect....487
Fault Overview....487
Lamp Reaction....487
Associated Faults....487
Fault Facts....487
Drive Cycle to Determine Fault Status....487
Possible Causes....487
Pin-Point Tests (SPN 2630 FMI 2)....490
Tools Required....490
SPN 2630 FMI 3 - CACOT Signal Out of Range HIGH....491
Fault Overview....491
Lamp Reaction....491
Associated Faults....491
Fault Facts....491
Drive Cycle to Determine Fault Status....491
Possible Causes....491
Pin-Point Tests (SPN 2630 FMI 3)....494
Tools Required....494
SPN 2630 FMI 4 - CACOT Signal Out of Range LOW....497
Fault Overview....497
Lamp Reaction....497
Associated Faults....497
Fault Facts....497
Drive Cycle to Determine Fault Status....497
Possible Causes....497
Pin-Point Tests (SPN 2630 FMI 4)....499
Tools Required....499
SPN 2630 FMI 16 - CACOT Undercooling....500
Fault Overview....500
Lamp Reaction....500
Associated Faults....500
Fault Facts....500
Drive Cycle to Determine Fault Status....500
Possible Causes....500
Pin-Point Tests (SPN 2630 FMI 2)....504
Tools Required....504
CCOSS Sensor (Crankcase Oil Separator Speed)....505
Overview of CCOSS Sensor Group....505
Overview....505
SPN 4227 FMI 7 - CC Oil Separator: Not spinning....506
Fault Overview....506
Lamp Reaction....506
Associated Faults....506
Fault Facts....506
Drive Cycle to Determine Fault Status....506
Possible Causes....506
Pin-Point Tests (SPN 4227 FMI 7)....509
Tools Required....509
CKP Sensor (Crankshaft Position)....511
Overview of CKP Sensor Group....511
Overview....511
SPN 637 FMI 8 - CKP signal noise....512
Fault Overview....512
Lamp Reaction....512
Associated Faults....512
Fault Facts....512
Drive Cycle to Determine Fault Status....512
Possible Causes....512
Pin-Point Tests....515
Tools Required....515
SPN 637 FMI 10 - CKP signal Inactive....519
Fault Overview....519
Lamp Reaction....519
Associated Faults....519
Fault Facts....519
Drive Cycle to Determine Fault Status....519
Possible Causes....519
Pin-Point Tests....523
Tools Required....523
CMP Sensor (Camshaft Position)....525
Overview of CMP Sensor Group....525
Overview....525
SPN 636 FMI 2 - CMP and CKP Synchronization Error....526
Fault Overview....526
Lamp Reaction....526
Associated Faults....526
Fault Facts....526
Drive Cycle to Determine Fault Status....526
Possible Causes....526
Pin-Point Tests....530
Tools Required....530
SPN 636 FMI 7 - CMP to CKP incorrect reference....535
Fault Overview....535
Lamp Reaction....535
Associated Faults....535
Fault Facts....535
Drive Cycle to Determine Fault Status....535
Possible Causes....535
DCU Power (Doser Control Unit)....537
Overview of DCU Power Sensor Group....537
Overview....537
SPN 609 FMI 19 - ACM not detected on J1939....538
Fault Overview....538
Lamp Reaction....538
Associated Faults....538
Fault Facts....538
Drive Cycle to Determine Fault Status....538
Possible Causes....538
Pin-Point Tests....543
Tools Required....543
SPN 5109 FMI 15 - DCU battery voltage too HIGH....554
Fault Overview....554
Lamp Reaction....554
Associated Faults....554
Fault Facts....554
Drive Cycle to Determine Fault Status....554
Possible Causes....554
SPN 5109 FMI 17 - DCU battery voltage too LOW....556
Fault Overview....556
Lamp Reaction....556
Associated Faults....556
Fault Facts....556
Drive Cycle to Determine Fault Status....556
Possible Causes....556
Pin-Point Tests (SPN 5109 FMI 17)....559
Tools Required....559
SPN 5109 FMI 19 - DCU not detected on J1939....560
Fault Overview....560
Lamp Reaction....560
Associated Faults....560
Fault Facts....560
Drive Cycle to Determine Fault Status....560
Possible Causes....560
Pin-Point Tests (SPN 5109 FMI 19)....565
Tools Required....565
DEF (Diesel Exhaust Fluid)....572
Overview of DEF Sensor Group....572
Overview....572
SPN 520668 FMI 31 - Controller Adaptation Outer Limits Reached (Low Reductant Delivery)....573
Fault Overview....573
Lamp Reaction....573
Associated Faults....573
Fault Facts....573
Drive Cycle to Determine Fault Status....573
Possible Causes....573
SPN 520669 FMI 31 - Controller Adaptation Inner Limits Reached (Low Reductant Delivery)....576
Fault Overview....576
Lamp Reaction....576
Associated Faults....576
Fault Facts....576
Drive Cycle to Determine Fault Status....576
Possible Causes....576
DEFSMH (Diesel Exhaust Fluid Supply Module Heater)....579
Overview of DEFSMH Sensor Group....579
Overview....579
SPN 5745 FMI 3 - DEF Dosing Unit Heater Out of Range HIGH....583
Fault Overview....583
Lamp Reaction....583
Associated Faults....583
Fault Facts....583
Drive Cycle to Determine Fault Status....583
Possible Causes....583
Pin-Point Tests (SPN 5745 FMI 3)....586
Tools Required....586
SPN 5745 FMI 4 - DEF Supply Module Heater Out of Range LOW....588
Fault Overview....588
Lamp Reaction....588
Associated Faults....588
Fault Facts....588
Drive Cycle to Determine Fault Status....588
Possible Causes....588
Pin-Point Tests (SPN 5745 FMI 4)....593
Tools Required....593
SPN 5745 FMI 18 - DEF Supply Module Heater below Warning Temperature ....600
Fault Overview....600
Lamp Reaction....600
Associated Faults....600
Fault Facts....600
Drive Cycle to Determine Fault Status....600
Possible Causes....600
Pin-Point Tests (SPN 5745 FMI 18)....604
Tools Required....604
SPN 5798 FMI 2 - DEF Supply Module Heater Temperature erratic, intermittent or incorrect....606
Fault Overview....606
Lamp Reaction....606
Associated Faults....606
Fault Facts....606
Drive Cycle to Determine Fault Status....606
Possible Causes....606
Pin-Point Tests (SPN 5798 FMI 2)....609
Tools Required....609
SPN 5798 FMI 10 - DEF Supply Module Heater Temperature abnormal rate of change....612
Fault Overview....612
Lamp Reaction....612
Associated Faults....612
Fault Facts....612
Drive Cycle to Determine Fault Status....612
Possible Causes....612
Pin-Point Tests (SPN 5798 FMI 10) ....615
Tools Required....615
DEFD (Diesel Exhaust Fluid Doser) Sensor....618
Overview of DEFD Sensor Group....618
Overview....618
SPN 5394 FMI 2 - DEF Dosing below desired (Low NOx conversion across SCR)....619
Fault Overview....619
Lamp Reaction....619
Associated Faults....619
Fault Facts....619
Drive Cycle to Determine Fault Status....619
Possible Causes....619
Pin-Point Tests (SPN 5394 FMI 2)....622
Tools Required....622
SPN 5394 FMI 5 - DEF Doser Valve open load/circuit....623
Fault Overview....623
Lamp Reaction....623
Associated Faults....623
Fault Facts....623
Drive Cycle to Determine Fault Status....623
Possible Causes....623
Pin-Point Tests (SPN 5394 FMI 5)....627
Tools Required....627
SPN 5394 FMI 7 - DEF Dosing Unit - Mechanical system not responding ....629
Fault Overview....629
Lamp Reaction....629
Associated Faults....629
Fault Facts....629
Drive Cycle to Determine Fault Status....629
Possible Causes....629
DEFLHR (Diesel Exhaust Fluid Line Heater Relay)....632
Overview of DEFLHR Sensor Group....632
Overview....632
SPN 5491 FMI 3 - DEF Line Heater Relay Open or short to PWR....634
Fault Overview....634
Lamp Reaction....634
Associated Faults....634
Fault Facts....634
Drive Cycle to Determine Fault Status....634
Possible Causes....634
Pin-Point Tests (SPN 5491 FMI 3)....637
Tools Required....637
SPN 5491 FMI 4 - DEF Line Heater Relay short to GND....641
Fault Overview....641
Lamp Reaction....641
Associated Faults....641
Fault Facts....641
Drive Cycle to Determine Fault Status....641
Possible Causes....641
Pin-Point Tests (SPN 5491 FMI 4)....643
Tools Required....643
DEFLP (Diesel Exhaust Fluid Line Pressure)....646
Overview of DEFLP Sensor Group....646
Overview....646
SPN 4334 FMI 2 - DEFLP signal erratic, intermittent or incorrect....649
Fault Overview....649
Lamp Reaction....649
Associated Faults....649
Fault Facts....649
Drive Cycle to Determine Fault Status....649
Possible Causes....649
SPN 4334 FMI 3 - DEFLP Signal Out of Range HIGH....653
Fault Overview....653
Lamp Reaction....653
Associated Faults....653
Fault Facts....653
Drive Cycle to Determine Fault Status....653
Possible Causes....653
Pin-Point Tests (SPN 4334 FMI 3)....656
Tools Required....656
SPN 4334 FMI 4 - DEFLP signal Out of Range LOW....658
Fault Overview....658
Lamp Reaction....658
Associated Faults....658
Fault Facts....658
Drive Cycle to Determine Fault Status....658
Possible Causes....658
Pin-Point Tests (SPN 4334 FMI 4)....661
Tools Required....661
SPN 4334 FMI 16 - DEF Absolute Pressure above maximum....664
Fault Overview....664
Lamp Reaction....664
Associated Faults....664
Fault Facts....664
Drive Cycle to Determine Fault Status....664
Possible Causes....664
SPN 4334 FMI 18 - DEF Absolute Pressure below normal....666
Fault Overview....666
Lamp Reaction....666
Associated Faults....666
Fault Facts....666
Drive Cycle to Determine Fault Status....666
Possible Causes....666
SPN 4337 FMI 2 - DEF Dosing Unit Temperature - Data Erratic, Intermittent, or Incorrect....669
Fault Overview....669
Lamp Reaction....669
Associated Faults....669
Fault Facts....669
Drive Cycle to Determine Fault Status....669
Possible Causes....669
Pin-Point Tests (SPN 4337 FMI 2)....672
Tools Required....672
SPN 4337 FMI 10 - DEF Dosing Unit Temperature abnormal rate of change....675
Fault Overview....675
Lamp Reaction....675
Associated Faults....675
Fault Facts....675
Drive Cycle to Determine Fault Status....675
Possible Causes....675
Pin-Point Tests (SPN 4337 FMI 10)....678
Tools Required....678
DEFSLH (Diesel Exhaust Fluid Supply Line Heater)....681
Overview of DEFSLH Sensor Group....681
Overview....681
SPN 4340 FMI 3 - DEF Supply Line Heater Short to PWR....683
Fault Overview....683
Lamp Reaction....683
Associated Faults....683
Fault Facts....683
Drive Cycle to Determine Fault Status....683
Possible Causes....683
Pin-Point Tests (SPN 4340 FMI 3)....686
Tools Required....686
SPN 4340 FMI 5 - DEF Supply Line Heater open load/circuit....689
Fault Overview....689
Lamp Reaction....689
Associated Faults....689
Fault Facts....689
Drive Cycle to Determine Fault Status....689
Possible Causes....689
Pin-Point Tests (SPN 4340 FMI 5)....693
Tools Required....693
DEFRLH (Diesel Exhaust Fluid Return Line Heater)....696
Overview of DEFRLH Sensor Group....696
Overview....696
SPN 4342 FMI 3 - DEF Return Line Heater Short to PWR....698
Fault Overview....698
Lamp Reaction....698
Associated Faults....698
Fault Facts....698
Drive Cycle to Determine Fault Status....698
Possible Causes....698
Pin-Point Tests (SPN 4342 FMI 3)....700
Tools Required....700
SPN 4342 FMI 5 - DEF Return Line Heater open load/circuit....703
Fault Overview....703
Lamp Reaction....703
Associated Faults....703
Fault Facts....703
Drive Cycle to Determine Fault Status....703
Possible Causes....703
Pin-Point Tests (SPN 4342 FMI 5)....707
Tools Required....707
DEFRV (Diesel Exhaust Fluid Reverting Valve)....710
Overview of DEFRV Sensor Group....710
Overview....710
SPN 4376 FMI 3 - DEF Reverting Control Valve short to PWR....711
Fault Overview....711
Lamp Reaction....711
Associated Faults....711
Fault Facts....711
Drive Cycle to Determine Fault Status....711
Possible Causes....711
Pin-Point Tests (SPN 4376 FMI 3)....714
Tools Required....714
SPN 4376 FMI 4 - DEF Reverting Control Valve short to GND....716
Fault Overview....716
Lamp Reaction....716
Associated Faults....716
Fault Facts....716
Drive Cycle to Determine Fault Status....716
Possible Causes....716
Pin-Point Tests (SPN 4376 FMI 4)....719
Tools Required....719
SPN 4376 FMI 7 - DEF Reverting Control Valve - Mechanical system not responding or out of adjustment....721
Fault Overview....721
Lamp Reaction....721
Associated Faults....721
Fault Fact....721
Drive Cycle to Determine Fault Status....721
Possible Causes....721
DEFPLH (Diesel Exhaust Fluid Pressure Line Heater)....723
Overview of DEFPLH Sensor Group....723
Overview....723
SPN 4344 FMI 3 - DEF Pressure Line Heater Short to PWR....726
Fault Overview....726
Lamp Reaction....726
Associated Faults....726
Fault Facts....726
Possible Causes....726
Pin-Point Tests (SPN 4344 FMI 3)....728
Tools Required....728
SPN 4344 FMI 5 - DEF Pressure Line Heater open load/circuit....731
Fault Overview....731
Lamp Reaction....731
Associated Faults....731
Fault Facts....731
Drive Cycle to Determine Fault Status....731
Possible Causes....731
Pin-Point Tests (SPN 4344 FMI 5)....735
Tools Required....735
DEFSP (Diesel Exhaust Fluid Supply Pump)....738
Overview of DEFSP Sensor Group....738
Overview....738
SPN 3361 FMI 2 - DEFSP Signal Erratic, Intermittent or Incorrect....742
Fault Overview....742
Lamp Reaction....742
Associated Faults....742
Fault Facts....742
Drive Cycle to Determine Fault Status....742
Possible Causes....742
Pin-Point Tests (SPN 3361 FMI 2)....745
Tools Required....745
SPN 3361 FMI 3 - DEFSP signal Out of Range HIGH....748
Fault Overview....748
Lamp Reaction....748
Associated Faults....748
Fault Facts....748
Drive Cycle to Determine Fault Status....748
Possible Causes....748
Pin-Point Tests (SPN 3361 FMI 3)....751
Tools Required....751
SPN 3361 FMI 4 - DEFSP Signal Out of Range LOW....753
Fault Overview....753
Lamp Reaction....753
Associated Faults....753
Fault Facts....753
Drive Cycle to Determine Fault Status....753
Possible Causes....753
Pin-Point Tests (SPN 3361 FMI 4)....756
Tools Required....756
SPN 3362 FMI 31 - DEF Dosing Unable to Prime....759
Fault Overview....759
Lamp Reaction....759
Associated Faults....759
Fault Facts....759
Drive Cycle to Determine Fault Status....759
Possible Causes....759
DEFTHV (Diesel Exhaust Fluid Tank Heater Valve)....764
Overview of DEFTHV....764
Overview....764
SPN 3363 FMI 3 - DEF Tank Heater Control Valve short to PWR....766
Fault Overview....766
Lamp Reaction....766
Associated Faults....766
Fault Facts....766
Drive Cycle to Determine Fault Status....766
Possible Causes....766
Pin-Point Tests (SPN 3363 FMI 3)....769
Tools Required....769
SPN 3363 FMI 4 - DEF Tank Heater Control Valve short to GND....772
Fault Overview....772
Lamp Reaction....772
Associated Faults....772
Fault Facts....772
Drive Cycle to Determine Fault Status....772
Possible Causes....772
Pin-Point Tests (SPN 3363 FMI 4)....775
Tools Required....775
SPN 3363 FMI 7 - DEF Tank Heater Control Valve Mechanical system not responding....777
Fault Overview....777
Lamp Reaction....777
Associated Faults....777
Drive Cycle to Determine Fault Status....777
Possible Causes....777
SPN 3363 FMI 16 - DEF Tank Heater Control Valve stuck open fault....780
Fault Overview....780
Lamp Reaction....780
Associated Faults....780
Fault Facts....780
Drive Cycle to Determine Fault Status....780
Possible Causes....780
SPN 3363 FMI 18 - DEF Tank Heater Control Valve unable to thaw frozen DEF....782
Fault Overview....782
Lamp Reaction....782
Associated Faults....782
Fault Facts....782
Drive Cycle to Determine Fault Status....782
Possible Causes....782
DEFTL & DEFTT (Diesel Exhaust Fluid Tank Level and Temperature) Sensor Module....785
Overview of DEFTL & DEFTT Sensor Group....785
Overview....785
SPN 1569 FMI 31 - SCR Tamperproof Warning & Protection System Inducement Severe....787
Fault Overview....787
Lamp Reaction....787
Associated Faults....787
Fault Facts....787
Drive Cycle to Determine Fault Status....787
Possible Causes....787
SPN 1761 FMI 1 - DEFTL Inducement (Level 3 - 4)....789
Fault Overview....789
Lamp Reaction....789
Associated Faults....789
Fault Facts....789
Drive Cycle to Determine Fault Status....789
Possible Causes....789
SPN 1761 FMI 3 - DEFTL signal Out of Range HIGH....791
Fault Overview....791
Lamp Reaction....791
Associated Faults....791
Fault Facts....791
Drive Cycle to Determine Fault Status....791
Possible Causes....791
SPN 1761 FMI 4 - DEFTL signal Out of Range LOW....793
Fault Overview....793
Lamp Reaction....793
Associated Faults....793
Fault Facts....793
Drive Cycle to Determine Fault Status....793
Possible Causes....793
SPN 1761 FMI 10 - DEF Level abnormal rate of change....795
Fault Overview....795
Lamp Reaction....795
Associated Faults....795
Fault Facts....795
Drive Cycle to Determine Fault Status....795
Possible Causes....795
SPN 1761 FMI 11 - DEFTL signal erratic, intermittent, or incorrect ....797
Fault Overview....797
Lamp Reaction....797
Associated Faults....797
Fault Facts....797
Drive Cycle to Determine Fault Status....797
Possible Causes....797
SPN 1761 FMI 17 - DEFTL Inducement Level 1....799
Fault Overview....799
Lamp Reaction....799
Associated Faults....799
Fault Facts....799
Drive Cycle to Determine Fault Status....799
Possible Causes....799
SPN 1761 FMI 18 - DEFTL Inducement Level 2....801
Fault Overview....801
Lamp Reaction....801
Associated Faults....801
Fault Facts....801
Drive Cycle to Determine Fault Status....801
Possible Causes....801
SPN 1761 FMI 19 - DEFTL not detected on J1939....803
Fault Overview....803
Lamp Reaction....803
Associated Faults....803
Fault Facts....803
Drive Cycle....803
Possible Causes....803
Pin-Point Tests SPN 1761 FMI 19....807
Tools Required....807
SPN 3031 FMI 2 - DEFTT signal erratic, intermittent, or incorrect....815
Fault Overview....815
Lamp Reaction....815
Associated Faults....815
Fault Facts....815
Drive Cycle to Determine Fault Status....815
Possible Causes....815
Pin-Point Tests (SPN 3031 FMI 2)....818
Tools Required....818
SPN 3031 FMI 3 - DEFTT Signal Out of Range HIGH....820
Fault Overview....820
Lamp Reaction....820
Associated Faults....820
Fault Facts....820
Drive Cycle to Determine Fault Status....820
Possible Causes....820
SPN 3031 FMI 4 - DEFTT signal Out of Range LOW....822
Fault Overview....822
Lamp Reaction....822
Associated Faults....822
Fault Facts....822
Drive Cycle to Determine Fault Status....822
Possible Causes....822
SPN 3521 FMI 11 - Improper Reductant in DEF Tank....824
Fault Overview....824
Lamp Reaction....824
Associated Faults....824
Fault Facts....824
Drive Cycle to Determine Fault Status....824
Possible Causes....824
SPN 4094 FMI 31- DEF below acceptable quality....826
Fault Overview....826
Lamp Reaction....826
Associated Faults....826
Fault Facts....826
Drive Cycle to Determine Fault Status....826
Possible Causes....826
SPN 5246 FMI 15 - SCR Tamper Proof Inducement Level 1 status....829
Fault Overview....829
Lamp Reaction....829
Associated Faults....829
Fault Facts....829
Drive Cycle to Determine Fault Status....829
Possible Causes....829
DEFSMH Relay (Diesel Exhaust Fluid Supply Module Heater Relay) ....831
Overview of DEFSMH Relay Sensor Group....831
Overview....831
SPN 5746 FMI 3 - DEF Supply Module Heater Relay short to PWR....833
Fault Overview....833
Lamp Reaction....833
Associated Faults....833
Fault Facts....833
Drive Cycle to Determine Fault Status....833
Possible Causes....833
Pin-Point Tests (SPN 5746 FMI 3)....836
Tools Required....836
SPN 5746 FMI 4 - DEF Supply Module Heater Relay short to GND....839
Fault Overview....839
Lamp Reaction....839
Associated Faults....839
Fault Facts....839
Drive Cycle to Determine Fault Status....839
Possible Causes....839
Pin-Point Tests (SPN 5746 FMI 4)....841
Tools Required....841
DOC Temperature Sensor Module....843
Overview of DOC / DPF Temperature Sensor Group....843
Overview....843
SPN 5742 FMI 3 - DPF Thermocouple Controller Out of Range HIGH....844
Fault Overview....844
Lamp Reaction....844
Associated Faults....844
Fault Facts....844
Drive Cycle to Determine Fault Status....844
Possible Causes....844
Pin-Point Tests (SPN 5742 FMI 3)....846
Tools Required....846
SPN 5742 FMI 4 - DPF Thermocouple Controller Out of Range LOW....847
Fault Overview....847
Lamp Reaction....847
Associated Faults....847
Fault Facts....847
Drive Cycle to Determine Fault Status....847
Possible Causes....847
Pin-Point Tests (SPN 5742 FMI 4)....849
Tools Required....849
SPN 5742 FMI 11 - DPF Thermocouple Controller signal erratic, intermittent, or incorrect....851
Fault Overview....851
Lamp Reaction....851
Associated Faults....851
Fault Facts....851
Drive Cycle to Determine Fault Status....851
Possible Causes....851
Pin-Point Tests (SPN 5742 FMI 11)....854
Tools Required....854
SPN 5742 FMI 12 - DOC/DPF Temperature sensor module internal error....856
Fault Overview....856
Lamp Reaction....856
Associated Faults....856
Fault Facts....856
Drive Cycle to Determine Fault Status....856
Possible Causes....856
SPN 5742 FMI 16 ? DPF Thermocouple Controller above Maximum Temperature....858
Fault Overview....858
Lamp Reaction....858
Associated Faults....858
Fault Facts....858
Drive Cycle to Determine Fault Status....858
Possible Causes....858
SPN 5742 FMI 19 - DOC/DPF Temperature module not detect J1939....860
Fault Overview....860
Lamp Reaction....860
Associated Faults....860
Fault Facts....860
Drive Cycle to Determine Fault Status....860
Possible Causes....860
Pin-Point Tests (SPN 5742 FMI 19)....864
Tools Required....864
DOCIT Sensor (Diesel Oxidation Catalyst Intake Temperature)....872
Overview of DOCIT Sensor Group....872
Overview....872
SPN 4765 FMI 0 - DOCIT above Critical Temperature....874
Fault Overview....874
Lamp Reaction....874
Associated Faults....874
Fault Facts....874
Drive Cycle to Determine Fault Status....874
Possible Causes....874
SPN 4765 FMI 2 - DOCIT Signal erratic, intermittent, or incorrect....877
Fault Overview....877
Lamp Reaction....877
Associated Faults....877
Fault Facts....877
Drive Cycle to Determine Fault Status....877
Possible Causes....877
SPN 4765 FMI 3 - DOCIT signal Out of Range HIGH....879
Fault Overview....879
Lamp Reaction....879
Associated Faults....879
Fault Facts....879
Drive Cycle to Determine Fault Status....879
Possible Causes....879
SPN 4765 FMI 4 - DOCIT Signal Out of Range LOW....881
Fault Overview....881
Lamp Reaction....881
Associated Faults....881
Fault Facts....881
Drive Cycle to Determine Fault Status....881
Possible Causes....881
SPN 4765 FMI 15 - DOCIT Above Warning Temperature....883
Fault Overview....883
Lamp Reaction....883
Associated Faults....883
Fault Facts....883
Drive Cycle to Determine Fault Status....883
Possible Causes....883
SPN 4765 FMI 16 - DOCIT Above Maximum Temperature....886
Fault Overview....886
Lamp Reaction....886
Associated Faults....886
Fault Facts....886
Drive Cycle to Determine Fault Status....886
Possible Causes....886
DPF (Diesel Particulate Filter) Sensor ....889
Overview of DPF Sensor....889
Overview....889
SPN 5397 FMI 31 - DPF regenerations are occurring too frequently....890
Fault Overview....890
Lamp Reaction....890
Associated Faults....890
Fault Facts....890
Drive Cycle to Determine Fault Status....890
Possible Causes....890
DPFDP / DPFOP (Diesel Particulate Filter Differential Pressure / Diesel Particulate Filter Outlet Pressure) Sensor....893
Overview of DPFDP / DPFOP Sensor....893
Overview....893
SPN 3251 FMI 2 - DPFDP signal erratic, intermittent, or incorrect....894
Fault Overview....894
Lamp Reaction....894
Associated Faults....894
Fault Facts....894
Drive Cycle to Determine Fault Status....894
Possible Causes....894
Pin-Point Tests (SPN 3251 FMI 2)....897
Tools Required....897
SPN 3251 FMI 3 - DPFDP signal Out of Range HIGH....898
Fault Overview....898
Lamp Reaction....898
Associated Faults....898
Fault Facts....898
Drive Cycle to Determine Fault Status....898
Possible Causes....898
Pin-Point Tests (SPN 3251 FMI 3)....901
Tools Required....901
SPN 3251 FMI 4 - DPFDP signal Out of Range LOW....903
Fault Overview....903
Lamp Reaction....903
Associated Faults....903
Fault Facts....903
Drive Cycle to Determine Fault Status....903
Possible Causes....903
Pin-Point Tests (SPN 3251 FMI 4)....906
Tools Required....906
SPN 3610 FMI 2 - DPFOP Signal Erratic, Intermittent, or Incorrect....909
Fault Overview....909
Lamp Reaction....909
Associated Faults....909
Fault Facts....909
Drive Cycle to Determine Fault Status....909
Possible Causes....909
Pin-Point Tests (SPN 3610 FMI 2)....912
Tools Required....912
SPN 3610 FMI 3 - DPFOP signal Out of Range HIGH....914
Fault Overview....914
Lamp Reaction....914
Associated Faults....914
Fault Facts....914
Drive Cycle to Determine Fault Status....914
Possible Causes....914
Pin-Point Tests (SPN 3610 FMI 3)....917
Tools Required....917
SPN 3610 FMI 4 - DPFOP Signal Out of Range LOW....919
Fault Overview....919
Lamp Reaction....919
Associated Faults....919
Fault Facts....919
Drive Cycle to Determine Fault Status....919
Possible Causes....919
Pin-Point Tests (SPN 3610 FMI 4)....922
Tools Required....922
DPFIT Sensor (Diesel Particulate Filter Intake Temperature)....925
Overview of DPFIT Sensor Group....925
Overview....925
SPN 3242 FMI 0 - DPFIT above Critical Temperature....926
Fault Overview....926
Lamp Reaction....926
Associated Faults....926
Fault Facts....926
Drive Cycle to Determine Fault Status....926
Possible Causes....926
SPN 3242 FMI 2 - DPFIT signal erratic, intermittent, or incorrect....929
Fault Overview....929
Lamp Reaction....929
Associated Faults....929
Fault Facts....929
Drive Cycle to Determine Fault Status....929
Possible Causes....929
SPN 3242 FMI 3 - DPFIT signal Out of Range HIGH....931
Fault Overview....931
Lamp Reaction....931
Associated Faults....931
Fault Facts....931
Drive Cycle to Determine Fault Status....931
Possible Causes....931
SPN 3242 FMI 4 - DPFIT signal Out of Range LOW....933
Fault Overview....933
Lamp Reaction....933
Associated Faults....933
Fault Facts....933
Drive Cycle to Determine Fault Status....933
Possible Causes....933
SPN 3242 FMI 15 - DPFIT above Warning Temperature....935
Fault Overview....935
Lamp Reaction....935
Associated Faults....935
Fault Facts....935
Drive Cycle to Determine Fault Status....935
Possible Causes....935
SPN 3242 FMI 16 - DPFIT above Maximum Temperature....938
Fault Overview....938
Lamp Reaction....938
Associated Faults....938
Fault Facts....938
Drive Cycle to Determine Fault Status....938
Possible Causes....938
SPN 4766 FMI 15 - DPFIT Above Warning Temperature....941
Fault Overview....941
Lamp Reaction....941
Associated Faults....941
Fault Facts....941
Drive Cycle to Determine Fault Status....941
Possible Causes....941
SPN 4766 FMI 16 - DPFIT Above Maximum Temperature....944
Fault Overview....944
Lamp Reaction....944
Associated Faults....944
Fault Facts....944
Drive Cycle to Determine Fault Status....944
Possible Causes....944
DPFOT Sensor (Diesel Particulate Filter Outlet Temperature)....947
Overview of DPFOT Sensor Group....947
Overview....947
SPN 3246 FMI 0 - DPFOT above Critical Temperature....948
Fault Overview....948
Lamp Reaction....948
Associated Faults....948
Fault Facts....948
Drive Cycle to Determine Fault Status....948
Possible Causes....948
SPN 3246 FMI 2 - DPFOT Signal Erratic, Intermittent, or Incorrect....951
Fault Overview....951
Lamp Reaction....951
Associated Faults....951
Fault Facts....951
Drive Cycle to Determine Fault Status....951
Possible Causes....951
SPN 3246 FMI 3 - DPFOT signal Out of Range HIGH....953
Fault Overview....953
Lamp Reaction....953
Associated Faults....953
Fault Facts....953
Drive Cycle to Determine Fault Status....953
Possible Causes....953
SPN 3246 FMI 4 - DPFOT Signal Out of Range LOW....955
Fault Overview....955
Lamp Reaction....955
Associated Faults....955
Fault Facts....955
Drive Cycle to Determine Fault Status....955
Possible Causes....955
SPN 3246 FMI 15 - DPFOT above Warning Temperature....957
Fault Overview....957
Lamp Reaction....957
Associated Faults....957
Fault Facts....957
Drive Cycle to Determine Fault Status....957
Possible Causes....957
SPN 3246 FMI 16 - DPFOT above Maximum Temperature....960
Fault Overview....960
Lamp Reaction....960
Associated Faults....960
Fault Facts....960
Drive Cycle to Determine Fault Status....960
Possible Causes....960
EBP Sensor (Exhaust Back Pressure)....963
Overview of EBP Sensor Group....963
Overview....963
SPN 1209 FMI 2 - EBP Signal erratic, intermittent, or incorrect....964
Fault Overview....964
Lamp Reaction....964
Associated Faults....964
Fault Facts....964
Drive Cycle to Determine Fault Status....964
Possible Causes....964
SPN 1209 FMI 3 - EBP Signal Out of Range HIGH....966
Fault Overview....966
Lamp Reaction....966
Associated Faults....966
Fault Facts....966
Drive Cycle to Determine Fault Status....966
Possible Causes....966
Pin-Point Tests (SPN 1209 FMI 3)....969
Tools Required....969
SPN 1209 FMI 4 - EBP Signal Out of Range LOW....971
Fault Overview....971
Lamp Reaction....971
Associated Faults....971
Fault Facts....971
Drive Cycle to Determine Fault Status....971
Possible Causes....971
Pin-Point Tests (SPN 1209 FMI 4)....974
Tools Required....974
EBPV (Exhaust Back Pressure Valve)....978
Overview of EBPV Sensor Group....978
Overview....978
SPN 5541 FMI 2 - TC1TOP signal erratic, intermittent, or incorrect ....979
Function....979
Lamp Reaction....979
Associated Faults....979
Fault Facts....979
Drive Cycle to Determine Fault Status....979
Possible Causes....979
SPN 5541 FMI 3 - TC1TOP signal Out of Range HIGH....981
Fault Overview....981
Lamp Reaction....981
Associated Faults....981
Fault Facts....981
Drive Cycle to Determine Fault Status....981
Possible Causes....981
Pin-Point Tests (SPN 5541 FMI 3)....983
Tools Required....983
SPN 5541 FMI 4 - TC1TOP signal Out of Range LOW....984
Fault Overview....984
Lamp Reaction....984
Associated Faults....984
Fault Facts....984
Drive Cycle to Determine Fault Status....984
Possible Causes....984
Pin-Point Tests (SPN 5541 FMI 4)....987
Tools Required....987
SPN 5542 FMI 15 - TC1TOP Above Desired....989
Fault Overview....989
Lamp Reaction....989
Associated Faults....989
Fault Facts....989
Drive Cycle to Determine Fault Status....989
Possible Causes....989
SPN 5543 FMI 3 - EBPC short to PWR....991
Fault Overview....991
Lamp Reaction....991
Associated Faults....991
Fault Facts....991
Drive Cycle to Determine Fault Status....991
Possible Causes....991
Pin-Point Tests (SPN 5543 FMI 3)....994
Tools Required....994
SPN 5543 FMI 4 - EBPC short to GND....997
Fault Overview....997
Lamp Reaction....997
Associated Faults....997
Fault Facts....997
Drive Cycle to Determine Fault Status....997
Possible Causes....997
Pin-Point Tests (SPN 5543 FMI 4)....999
Tools Required....999
SPN 5543 FMI 5 - EBPC open load/circuit....1000
Fault Overview....1000
Lamp Reaction....1000
Associated Faults....1000
Fault Facts....1000
Drive Cycle to Determine Fault Status....1000
Possible Causes....1000
Pin-Point Tests (SPN 5543 FMI 5)....1003
Tools Required....1003
ECB1 (Engine Compression Brake Output 1)....1005
Overview of ECB1 Sensor Group....1005
Overview....1005
SPN 4287 FMI 0 - ECBP above desired level....1006
Fault Overview....1006
Lamp Reaction....1006
Associated Faults....1006
Fault Facts....1006
Drive Cycle to Determine Fault Status....1006
Possible Causes....1006
SPN 4287 FMI 1 - ECPB below desired level....1009
Fault Overview....1009
Lamp Reaction....1009
Associated Faults....1009
Fault Facts....1009
Drive Cycle to Determine Fault Status....1009
Possible Causes....1009
SPN 4287 FMI 3 - ECBP signal Out of Range HIGH....1011
Fault Overview....1011
Lamp Reaction....1011
Associated Faults....1011
Fault Facts....1011
Drive Cycle to Determine Fault Status....1011
Possible Causes....1011
Pin-Point Tests SPN 4287 FMI 3....1015
Tools Required....1015
SPN 4287 FMI 4 - ECBP signal Out of Range LOW....1023
Fault Overview....1023
Lamp Reaction....1023
Associated Faults....1023
Fault Facts....1023
Drive Cycle to Determine Fault Status....1023
Possible Causes....1023
Pin-Point Tests (SPN 4287 FMI 4)....1026
Tools Required....1026
ECI Circuit (Engine Crank Inhibit)....1027
Overview of ECI Circuit....1027
Function....1027
Location....1027
Tools....1027
ECI Circuit Diagnostics....1029
ECI Circuit Operation....1032
DDS Circuit....1032
Ignition Switch....1032
ECI Circuit....1032
Engine Control Module (ECM)....1032
Starter Relay....1032
Clutch Switch....1032
Neutral Switch....1032
WTEC MD with Auto Neutral....1032
Fault Detection / Management....1033
ECM (Engine Control Module)....1034
Overview of ECM Sensor ....1034
Overview....1034
SPN 108 FMI 2 - BARO Signal Erratic, Intermittent or Incorrect....1035
Fault Overview....1035
Lamp Reaction....1035
Associated Faults....1035
Fault Facts....1035
Drive Cycles....1035
Possible Cause....1035
SPN 108 FMI 3 - BARO signal Out of Range HIGH....1037
Fault Overview....1037
Lamp Reaction....1037
Associated Faults....1037
Fault Facts....1037
Drive Cycle to Determine Fault Status....1037
Possible Causes....1037
SPN 108 FMI 4 - BARO signal Out of Range LOW....1039
Fault Overview....1039
Lamp Reaction....1039
Associated Faults....1039
Fault Facts....1039
Drive Cycle to Determine Fault Status....1039
Possible Causes....1039
SPN 158 FMI 15 - ECM Switched voltage too HIGH....1041
Fault Overview....1041
Lamp Reaction....1041
Associated Faults....1041
Fault Facts....1041
Drive Cycle to Determine Fault Status....1041
Possible Causes....1041
SPN 158 FMI 17 - ECM Switched voltage too LOW....1043
Fault Overview....1043
Lamp Reaction....1043
Associated Faults....1043
Fault Facts....1043
Drive Cycle to Determine Fault Status....1043
Possible Causes....1043
Pin-Point Tests (SPN 158 FMI 17)....1047
Tools Required....1047
SPN 628 FMI 12 - ECM Memory Error....1052
Fault Overview....1052
Lamp Reaction....1052
Associated Faults....1052
Fault Facts....1052
Drive Cycle to Determine Fault Status....1052
Possible Causes....1052
SPN 629 FMI 0 - ECM Error - CPU Load Excessively HIGH....1054
Fault Overview....1054
Lamp Reaction....1054
Associated Faults....1054
Fault Facts....1054
Drive Cycle to Determine Fault Status....1054
Possible Causes....1054
SPN 629 FMI 8 - ECM Error - Engine Off Timer fault....1056
Fault Overview....1056
Lamp Reaction....1056
Associated Faults....1056
Fault Facts....1056
Drive Cycle to Determine Fault Status....1056
Possible Causes....1056
SPN 629 FMI 12 - ECM Internal chip Error....1059
Fault Overview....1059
Lamp Reaction....1059
Associated Faults....1059
Fault Facts....1059
Drive Cycle to Determine Fault Status....1059
Possible Causes....1059
SPN 1136 FMI 0 - ECM Error - over temperature....1061
Fault Overview....1061
Lamp Reaction....1061
Associated Faults....1061
Fault Facts....1061
Drive Cycle to Determine Fault Status....1061
Possible Causes....1061
SPN 1387 FMI 31 - Altitude Reference Adder Fault....1063
Fault Overview....1063
Lamp Reaction....1063
Associated Faults....1063
Fault Facts....1063
Drive Cycle to Determine Fault Status....1063
Possible Causes....1063
Pin-Point Tests....1068
Tools Required....1068
ECT1 Sensor (Engine Coolant Temperature 1)....1071
Overview of ECT1 Sensor Group....1071
Overview....1071
SPN 110 FMI 2 - ECT1 signal erratic, intermittent, or incorrect....1073
Fault Overview....1073
Lamp Reaction....1073
Associated Faults....1073
Fault Facts....1073
Drive Cycle to Determine Fault Status....1073
Possible Causes....1073
Pin-Point Tests (SPN 110 FMI 2)....1076
Tools Required....1076
SPN 110 FMI 3 - ECT1 Signal Out of Range HIGH....1078
Fault Overview....1078
Lamp Reaction....1078
Associated Faults....1078
Fault Facts....1078
Drive Cycle to Determine Fault Status....1078
Possible Causes....1078
Pin-Point Tests (SPN 110 FMI 3)....1081
Tools Required....1081
SPN 110 FMI 4 - ECT1 signal Out of Range LOW....1084
Fault Overview....1084
Lamp Reaction....1084
Associated Faults....1084
Fault Facts....1084
Drive Cycle to Determine Fault Status....1084
Possible Causes....1084
Pin-Point Tests (SPN 110 FMI 4)....1086
Tools Required....1086
SPN 110 FMI 17 - ECT1 stuck in range Low....1087
Fault Overview....1087
Lamp Reaction....1087
Associated Faults....1087
Fault Facts....1087
Drive Cycle to Determine Fault Status....1087
Possible Causes....1087
SPN 110 FMI 18 - Engine Coolant System below closed loop minimum Temperature....1089
Fault Overview....1089
Lamp Reaction....1089
Associated Faults....1089
Fault Facts....1089
Drive Cycle to Determine Fault Status....1089
Possible Causes....1089
SPN 1659 FMI 20 - ECT1 below expected: Check Thermostat....1091
Fault Overview....1091
Lamp Reaction....1091
Associated Faults....1091
Fault Facts....1091
Drive Cycle to Determine Fault Status....1091
Possible Causes....1091
Pin-Point Tests (SPN 1659 FMI 20)....1094
Tools Required....1094
EFP (Engine Fuel Pump)....1095
Overview of EFP Group....1095
Overview....1095
SPN 94 FMI 0 - Fuel Delivery Pressure above Critical....1096
Fault Overview....1096
Lamp Reaction....1096
Associated Faults....1096
Fault Facts....1096
Drive Cycle to Determine Fault Status....1096
Possible Causes....1096
SPN 94 FMI 1 - Fuel Delivery Pressure below Critical....1098
Fault Overview....1098
Lamp Reaction....1098
Associated Faults....1098
Fault Facts....1098
Drive Cycle to Determine Fault Status....1098
Possible Causes....1098
SPN 931 FMI 3 - EFP short to PWR....1100
Fault Overview....1100
Lamp Reaction....1100
Associated Faults....1100
Fault Facts....1100
Drive Cycle to Determine Fault Status....1100
Possible Causes....1100
Pin-Point Test SPN 931 FMI 3....1103
Tools Required....1103
SPN 931 FMI 4 - EFP open load / circuit or short to GND....1106
Fault Overview....1106
Lamp Reaction....1106
Associated Faults....1106
Fault Facts....1106
Drive Cycle to Determine Fault Status....1106
Possible Causes....1106
Pin-Point Test SPN 931 FMI 4....1109
Tools Required....1109
EGR Actuator (Exhaust Gas Recirculation)....1115
Overview of EGR Actuator Sensor Group....1115
Overview....1115
SPN 27 FMI 0 - EGRP fault: over temperature....1117
Fault Overview....1117
Lamp Reaction....1117
Associated Faults....1117
Fault Facts....1117
Drive Cycle to Determine Fault Status....1117
Possible Causes....1117
SPN 27 FMI 14 - EGR internal circuit failure....1119
Fault Overview....1119
Lamp Reaction....1119
Associated Faults....1119
Fault Facts....1119
Drive Cycle to Determine Fault Status....1119
Possible Causes....1119
SPN 2791 FMI 2 - EGR feedback communication fault....1121
Fault Overview....1121
Lamp Reaction....1121
Associated Faults....1121
Fault Facts....1121
Drive Cycle to Determine Fault Status....1121
Possible Causes....1121
Pin-Point Tests (SPN 2791 FMI 2)....1125
Tools Required....1125
SPN 2791 FMI 3 - EGRV supply voltage is too HIGH....1127
Fault Overview....1127
Lamp Reaction....1127
Associated Faults....1127
Fault Facts....1127
Drive Cycle to Determine Fault Status....1127
Possible Causes....1127
SPN 2791 FMI 4 - EGRV supply voltage is too LOW....1129
Fault Overview....1129
Lamp Reaction....1129
Associated Faults....1129
Fault Facts....1129
Drive Cycle to Determine Fault Status....1129
Possible Causes....1129
Pin-Point Tests (SPN 2791 FMI 4)....1131
Tools Required....1131
SPN 2791 FMI 7 - EGR Valve unable to achieve commanded position....1133
Fault Overview....1133
Lamp Reaction....1133
Associated Faults....1133
Fault Facts....1133
Drive Cycle to Determine Fault Status....1133
Possible Causes....1133
SPN 2791 FMI 8 - EGR valve not receiving ECM PWM signal....1135
Fault Overview....1135
Lamp Reaction....1135
Associated Faults....1135
Fault Facts....1135
Drive Cycle to Determine Fault Status....1135
Possible Causes....1135
Pin-Point Tests (SPN 2791 FMI 8)....1139
Tools Required....1139
SPN 2791 FMI 12 - EGR Valve Internal self test fault....1144
Fault Overview....1144
Lamp Reaction....1144
Associated Fault....1144
Fault Facts....1144
Drive Cycle to Determine Fault Status....1144
Possible Causes....1144
SPN 2791 FMI 14 - EGR Valve did not seat....1146
Fault Overview....1146
Lamp Reaction....1146
Associated Fault....1146
Fault Facts....1146
Drive Cycle to Determine Fault Status....1146
Possible Causes....1146
SPN 4752 FMI 4 - EGR Cooler Efficiency: EGR Outlet Temp above expected....1148
Fault Overview....1148
Lamp Reaction....1148
Associated Faults....1148
Fault Facts....1148
Drive Cycle to Determine Fault Status....1148
Possible Causes....1148
EGT Sensor (Exhaust Gas Temperature)....1151
Overview of EGT Sensor Group....1151
Overview....1151
SPN 173 FMI 2 - EGT signal erratic, intermittent, or incorrect....1153
Fault Overview....1153
Lamp Reaction....1153
Associated Faults....1153
Fault Facts....1153
Drive Cycle to Determine Fault Status....1153
Possible Causes....1153
Pin-Point Tests (SPN 173 FMI 2)....1156
Tools Required....1156
SPN 173 FMI 3 - EGT Signal Out of Range HIGH....1158
Fault Overview....1158
Lamp Reaction....1158
Associated Faults....1158
Fault Facts....1158
Drive Cycle to Determine Fault Status....1158
Possible Causes....1158
Pin-Point Tests (SPN 173 FMI 3)....1161
Tools Required....1161
SPN 173 FMI 4 - EGT Signal Out of Range LOW....1164
Fault Overview....1164
Lamp Reaction....1164
Associated Faults....1164
Fault Facts....1164
Drive Cycle to Determine Fault Status....1164
Possible Causes....1164
Pin-Point Tests (SPN 173 FMI 4)....1166
Tools Required....1166
Engine....1167
Overview of Engine Sensor ....1167
SPN 188 FMI 0 - Engine Low Idle RPM above normal....1168
Fault Overview....1168
Lamp Reaction....1168
Associated Faults....1168
Fault Facts....1168
Drive Cycle to Determine Fault Status....1168
Possible Causes....1168
SPN 188 FMI 1 - Engine Low Idle RPM below normal....1170
Fault Overview....1170
Lamp Reaction....1170
Associated Faults....1170
Fault Facts....1170
Drive Cycle to Determine Fault Status....1170
Possible Causes....1170
SPN 1322 FMI 31 Misfire - Multiple Cylinders....1173
Fault Overview....1173
Lamp Reaction....1173
Associated Faults....1173
Fault Facts....1173
Drive Cycle to Determine Fault Status....1173
Possible Causes....1173
SPN 1323 FMI 31 - Misfire - Cylinder 1....1177
Fault Overview....1177
Lamp Reaction....1177
Associated Faults....1177
Fault Facts....1177
Drive Cycle to Determine Fault Status....1177
Possible Causes....1177
Pin-Point Tests....1181
Tools Required....1181
SPN 1324 FMI 31 - Misfire - Cylinder 2....1182
Fault Overview....1182
Lamp Reaction....1182
Associated Faults....1182
Fault Facts....1182
Drive Cycle to Determine Fault Status....1182
Possible Causes....1182
Pin-Point Tests....1186
Tools Required....1186
SPN 1325 FMI 31 - Misfire - Cylinder 3....1187
Fault Overview....1187
Lamp Reaction....1187
Associated Faults....1187
Fault Facts....1187
Drive Cycle to Determine Fault Status....1187
Possible Causes....1187
Pin-Point Tests....1191
Tools Required....1191
SPN 1326 FMI 31 - Misfire - Cylinder 4....1192
Fault Overview....1192
Lamp Reaction....1192
Associated Faults....1192
Fault Facts....1192
Drive Cycle to Determine Fault Status....1192
Possible Causes....1192
Pin-Point Tests....1196
Tools Required....1196
SPN 1327 FMI 31 - Misfire - Cylinder 5....1197
Fault Overview....1197
Lamp Reaction....1197
Associated Faults....1197
Fault Facts....1197
Drive Cycle to Determine Fault Status....1197
Possible Causes....1197
Pin-Point Tests....1201
Tools Required....1201
SPN 1328 FMI 31 - Misfire - Cylinder 6....1202
Fault Overview....1202
Lamp Reaction....1202
Associated Faults....1202
Fault Facts....1202
Drive Cycle to Determine Fault Status....1202
Possible Causes....1202
Pin-Point Tests....1206
Tools Required....1206
SPN 5395 FMI 0 Engine unable to achieve desired idle torque (too high)....1207
Fault Overview....1207
Lamp Reaction....1207
Associated Faults....1207
Fault Facts....1207
Drive Cycle to Determine Fault Status....1207
Possible Causes....1207
SPN 5395 FMI 1 Engine unable to achieve desired idle torque (too low)....1210
Fault Overview....1210
Lamp Reaction....1210
Associated Faults....1210
Fault Facts....1210
Drive Cycle to Determine Fault Status....1210
Possible Causes....1210
EOP Sensor (Engine Oil Pressure)....1213
Overview of EOP Sensor Group....1213
Overview....1213
SPN 100 FMI 3 - EOP signal Out of Range HIGH....1214
Fault Overview....1214
Lamp Reaction....1214
Associated Faults....1214
Fault Facts....1214
Drive Cycle to Determine Fault Status....1214
Possible Causes....1214
Pin-Point Tests (SPN 100 FMI 3)....1217
Tools Required....1217
SPN 100 FMI 4 - EOP Signal Out of Range LOW....1219
Fault Overview....1219
Lamp Reaction....1219
Associated Faults....1219
Fault Facts....1219
Drive Cycle to Determine Fault Status....1219
Possible Causes....1219
Pin-Point Tests (SPN 100 FMI 4)....1222
Tools Required....1222
EOT Sensor (Engine Oil Temperature)....1225
Overview of EOT Sensor Group....1225
Overview....1225
SPN 175 FMI 2 - EOT signal erratic, intermittent, or incorrect....1227
Fault Overview....1227
Lamp Reaction....1227
Associated Faults....1227
Fault Facts....1227
Drive Cycle to Determine Fault Status....1227
Possible Causes....1227
Pin-Point Tests (SPN 175 FMI 2)....1230
Tools Required....1230
SPN 175 FMI 3 - EOT signal Out of Range HIGH....1232
Fault Overview....1232
Lamp Reaction....1232
Associated Faults....1232
Fault Facts....1232
Drive Cycle to Determine Fault Status....1232
Possible Causes....1232
Pin-Point Tests (SPN 175 FMI 3)....1235
Tools Required....1235
SPN 175 FMI 4 - EOT signal Out of Range LOW....1238
Fault Overview....1238
Lamp Reaction....1238
Associated Faults....1238
Fault Facts....1238
Drive Cycle to Determine Fault Status....1238
Possible Causes....1238
Pin-Point Tests (SPN 175 FMI 4)....1240
Tools Required....1240
SPN 175 FMI 7 - EOT not warming along with engine....1241
Fault Overview....1241
Lamp Reaction....1241
Associated Faults....1241
Fault Facts....1241
Drive Cycle to Determine Fault Status....1241
Possible Causes....1241
Pin-Point Tests (SPN 175 FMI 7)....1244
Tools Required....1244
ETP (Engine Throttle Valve Position)....1247
Overview of ETP Sensor Group....1247
Overview....1247
SPN 51 FMI 3 - ETP signal Out of Range HIGH....1249
Fault Overview....1249
Lamp Reaction....1249
Associated Faults....1249
Drive Cycle to Determine Fault Status....1249
Possible Causes....1249
SPN 51 FMI 4 - ETP signal Out of Range LOW....1251
Fault Overview....1251
Lamp Reaction....1251
Associated Faults....1251
Fault Facts....1251
Drive Cycle to Determine Fault Status....1251
Possible Causes....1251
Pin-Point Tests (SPN 51 FMI 4)....1254
Tools Required....1254
SPN 51 FMI 7 - ETP does not agree with commanded position....1258
Fault Overview....1258
Lamp Reaction....1258
Associated Faults....1258
Fault Facts....1258
Drive Cycle to Determine Fault Status....1258
Possible Causes....1258
SPN 3464 FMI 31 - Intake Throttle Valve short circuit fault....1260
Fault Overview....1260
Lamp Reaction....1260
Associated Faults....1260
Fault Facts....1260
Drive Cycle to Determine Fault Status....1260
Possible Causes....1260
Pin-Point Tests (SPN 3464 FMI 31)....1263
Tools Required....1263
EWPS (Engine Warning Protection System)....1265
Overview of EWPS Sensor Group....1265
Overview....1265
Standard Warning....1265
3-way Warning....1265
3-way Protection....1265
Warning (Amber Triangle Light):....1266
Critical (Exclamation Mark Stop Lamp):....1266
Event log (if equipped):....1266
EWPS Programmable Parameters....1266
ECT Warning Temperature:....1266
ECT Critical Temperature:....1266
EOP Engine Speed Region Boundary 1 (600 RPM):....1266
EOP Engine Speed Region Boundary 2 (800 RPM):....1266
EOP Engine Speed Region Boundary 3 (1000 RPM):....1266
EOP Warning Pressure for Region 1 (10 psi / 69 kPa):....1266
EOP Warning pressure for Region 2 (16 psi / 110 kPa):....1266
EOP Warning Pressure for Region 3 (20 psi / 138 kPa):....1267
EOP Critical Pressure for Region 1 (7.5 psi / 52 kPa):....1267
EOP Critical Pressure for Region 2 (12 psi / 83 kPa):....1267
EOP Critical Pressure for Region 3. (15 psi / 103 kPa):....1267
SPN 100 FMI 1 - Engine Oil System below Critical Pressure....1268
Fault Overview....1268
Associated Faults....1268
Fault Facts....1268
Drive Cycle to Determine Fault Status....1268
Possible Causes....1268
SPN 100 FMI 18 - Engine Oil System below Warning Pressure....1270
Fault Overview....1270
Associated Faults....1270
Fault Facts....1270
Drive Cycle to Determine Fault Status....1270
Possible Causes....1270
SPN 110 FMI 0 - Engine Cooling System above Critical Temperature....1272
Fault Overview....1272
Lamp Reaction....1272
Associated Faults....1272
Fault Facts....1272
Drive Cycle to Determine Fault Status....1272
Possible Causes....1272
SPN 110 FMI 15 - Engine Cooling System above Warning Temperature....1274
Fault Overview....1274
Lamp Reaction....1274
Associated Faults....1274
Fault Facts....1274
Drive Cycle to Determine Fault Status....1274
Possible Causes....1274
SPN 110 FMI 16 - ECT1 stuck in range High....1276
Fault Overview....1276
Lamp Reaction....1276
Associated Faults....1276
Fault Facts....1276
Drive Cycle to Determine Fault Status....1276
Possible Causes....1276
SPN 111 FMI 1 - ECL Below Warning / Critical Level....1278
Fault Overview....1278
Lamp Reaction....1278
Associated Faults....1278
Fault Facts....1278
Drive Cycle to Determine Fault Status....1278
Possible Causes....1278
Pin-Point Tests (SPN 111 FMI 31)....1280
SPN 111 FMI 2 - ECL signal erratic, intermittent, or incorrect....1281
Fault Overview....1281
Lamp Reaction....1281
Associated Faults....1281
Fault Facts....1281
Drive Cycle to Determine Fault Status....1281
Possible Causes....1281
Pin-Point Tests....1283
Tools Required....1283
SPN 175 FMI 15 - Engine Oil System above Warning Temperature....1284
Fault Overview....1284
Lamp Reaction....1284
Associated Faults....1284
Fault Facts....1284
Drive Cycle to Determine Fault Status....1284
Possible Causes....1284
Pin-Point Tests (SPN 175 FMI 15)....1287
Tools Required....1287
SPN 190 FMI 0 - Engine overspeed - Most Severe Level....1290
Fault Overview....1290
Lamp Reaction....1290
Associated Faults....1290
Fault Facts....1290
Drive Cycle to Determine Fault Status....1290
Possible Causes....1290
SPN 593 FMI 31 - Engine Stopped by IST....1292
Function....1292
Tools....1292
Idle Shutdown Warning....1292
Engine Idle Shutdown Timer (IST) for California ESS Compliant Engines....1292
CARB Idle Shutdown Timer (IST) Conditions....1293
Idle Shutdown Timer (IST) (Federal ? Optional)....1293
Federal IST Conditions....1293
Common Enable Conditions for All Federal IST Options....1293
Federal IST Mode 1: PTO Operation Option Enable Conditions....1294
Federal IST Mode 2: No Load/Light Load Limit Option Enable Conditions....1294
Federal IST Mode 3: Tamper Proof Option Enable Conditions....1294
Fault Detection / Management....1294
SPN 1378 FMI 31 - Change Engine Oil Service Interval....1295
Fault Overview....1295
Lamp Reaction....1295
Associated Faults....1295
Fault Facts....1295
Drive Cycle to Determine Fault Status....1295
Possible Causes....1295
SPN 3936 FMI 0 - DPF Soot Load ? Severe De-Rate....1297
Fault Overview....1297
Lamp Reaction....1297
Associated Faults....1297
Fault Facts....1297
Drive Cycle to Determine Fault Status....1297
Possible Causes....1297
FDP (Fuel Delivery Pressure) Sensor....1301
Overview of FDP Sensor Group....1301
Overview....1301
SPN 94 FMI 3 - FDP signal Out of Range HIGH....1303
Fault Overview....1303
Lamp Reaction....1303
Associated Faults....1303
Fault Facts....1303
Drive Cycle to Determine Fault Status....1303
Possible Causes....1303
Pin-Point Tests (SPN 94 FMI 3)....1306
Tools Required....1306
SPN 94 FMI 4 - FDP signal Out of Range LOW....1308
Fault Overview....1308
Lamp Reaction....1308
Associated Faults....1308
Fault Facts....1308
Drive Cycle to Determine Fault Status....1308
Possible Causes....1308
Pin-Point Tests (SPN 94 FMI 4)....1311
Tools Required....1311
SPN 94 FMI 17 - Fuel Delivery Pressure below minimum....1314
Fault Overview....1314
Lamp Reaction....1314
Associated Faults....1314
Fault Facts....1314
Drive Cycle to Determine Fault Status....1314
Possible Causes....1314
SPN 94 FMI 18 - Fuel Delivery Pressure below min during cranking....1316
Fault Overview....1316
Lamp Reaction....1316
Associated Faults....1316
Fault Facts....1316
Drive Cycles....1316
Possible Causes....1316
FLI (Fuel Level Signal)....1318
Overview of FLI Sensor Group....1318
Overview....1318
SPN 96 FMI 3 - Fuel Level signal Out of Range HIGH....1319
Fault Overview....1319
Lamp Reaction....1319
Associated Faults....1319
Fault Facts....1319
Drive Cycle to Determine Fault Status....1319
Possible Causes....1319
SPN 96 FMI 4 - Fuel Level signal Out of Range LOW....1321
Fault Overview....1321
Lamp Reaction....1321
Associated Faults....1321
Fault Facts....1321
Drive Cycle to Determine Fault Status....1321
Possible Causes....1321
SPN 96 FMI 19 - Fuel Level not detected on J1939....1323
Fault Overview....1323
Lamp Reaction....1323
Associated Faults....1323
Fault Facts....1323
Drive Cycle to Determine Fault Status....1323
Possible Causes....1323
IAHC (Intake Air Heater Control)....1325
Overview of IAHC Group....1325
Overview....1325
SPN 729 FMI 3 - IAHC short to PWR....1326
Fault Overview....1326
Lamp Reaction....1326
Associated Faults....1326
Fault Facts....1326
Drive Cycle to Determine Fault Status....1326
Possible Causes....1326
Pin-Point Tests (SPN 729 FMI 3)....1328
Tools Required....1328
SPN 729 FMI 4 - IAHC short to GND....1329
Fault Overview....1329
Lamp Reaction....1329
Associated Faults....1329
Fault Facts....1329
Drive Cycle to Determine Fault Status....1329
Possible Causes....1329
Pin-Point Tests....1331
Tools Required....1331
SPN 729 FMI 5 - IAHC open load / circuit....1332
Fault Overview....1332
Lamp Reaction....1332
Associated Faults....1332
Fault Facts....1332
Drive Cycle to Determine Fault Status....1332
Possible Causes....1332
Pin-Point Tests (SPN 729 FMI 5)....1334
Tools Required....1334
SPN 729 FMI 18 - IAH Monitor fault: Lack of Heat in the Intake Manifold....1337
Fault Overview....1337
Lamp Reaction....1337
Associated Faults....1337
Fault Facts....1337
Drive Cycle to Determine Fault Status....1337
Possible Causes....1337
Pin-Point Tests....1340
Tools Required....1340
ICP Sensor (Injection Control Pressure)....1341
Overview of ICP Sensor Group....1341
Overview....1341
SPN 164 FMI 0 - ICP above KOEO Specification....1342
Fault Overview....1342
Lamp Reaction....1342
Associated Faults....1342
Fault Facts....1342
Drive Cycle to Determine Fault Status....1342
Possible Causes....1342
SPN 164 FMI 1 - ICP Unable to Build During Engine Cranking....1344
Fault Overview....1344
Lamp Reaction....1344
Associated Faults....1344
Fault Facts....1344
Drive Cycle to Determine Fault Status....1344
Possible Causes....1344
SPN 164 FMI 3 - ICP signal Out of Range HIGH....1347
Fault Overview....1347
Lamp Reaction....1347
Associated Faults....1347
Fault Facts....1347
Drive Cycle to Determine Fault Status....1347
Possible Causes....1347
Pin-Point Tests (SPN 164 FMI 3)....1351
Tools Required....1351
SPN 164 FMI 4 - ICP signal Out of Range LOW....1358
Fault Overview....1358
Lamp Reaction....1358
Associated Faults....1358
Fault Facts....1358
Drive Cycle to Determine Fault Status....1358
Possible Causes....1358
Pin-Point Tests (SPN 164 FMI 4)....1361
Tools Required....1361
SPN 164 FMI 15 - ICP too high during test....1363
Fault Overview....1363
Lamp Reaction....1363
Associated Faults....1363
Fault Facts....1363
Drive Cycle to Determine Fault Status....1363
Possible Causes....1363
SPN 164 FMI 16 - ICP above desired level....1366
Fault Overview....1366
Lamp Reaction....1366
Associated Faults....1366
Fault Facts....1366
Drive Cycle to Determine Fault Status....1366
Possible Causes....1366
SPN 164 FMI 17 - ICP unable to build during test....1369
Fault Overview....1369
Lamp Reaction....1369
Associated Faults....1369
Fault Facts....1369
Drive Cycle to Determine Fault Status....1369
Possible Causes....1369
SPN 164 FMI 18 - ICP below desired level....1373
Fault Overview....1373
Lamp Reaction....1373
Associated Faults....1373
Fault Facts....1373
Drive Cycle to Determine Fault Status....1373
Possible Causes....1373
IMP (Intake Manifold Pressure)....1377
Overview of IMP Sensor Group....1377
Overview....1377
SPN 102 FMI 2 - IMP signal erratic, intermittent, or incorrect....1378
Fault Overview....1378
Lamp Reaction....1378
Associated Faults....1378
Fault Facts....1378
Drive Cycle to Determine Fault Status....1378
Possible Causes....1378
SPN 102 FMI 3 - IMP signal Out of Range HIGH....1380
Fault Overview....1380
Lamp Reaction....1380
Associated Faults....1380
Fault Facts....1380
Drive Cycle to Determine Fault Status....1380
Possible Causes....1380
Pin-Point Tests (SPN 102 FMI 3)....1383
Tools Required....1383
SPN 102 FMI 4 - IMP signal Out of Range LOW....1384
Fault Overview....1384
Lamp Reaction....1384
Associated Faults....1384
Fault Facts....1384
Drive Cycle to Determine Fault Status....1384
Possible Causes....1384
Pin-Point Tests (SPN 102 FMI 4)....1387
Tools Required....1387
SPN 102 FMI 7 - IMP signal not responding as expected....1390
Fault Overview....1390
Lamp Reaction....1390
Associated Faults....1390
Fault Facts....1390
Drive Cycle to Determine Fault Status....1390
Possible Causes....1390
SPN 102 FMI 10 - Boost slow response fault....1392
Fault Overview....1392
Lamp Reaction....1392
Associated Faults....1392
Fault Facts....1392
Drive Cycle to Determine Fault Status....1392
Possible Causes....1392
SPN 102 FMI 16 - Overboost....1397
Fault Overview....1397
Lamp Reaction....1397
Associated Faults....1397
Fault Facts....1397
Drive Cycle to Determine Fault Status....1397
Possible Causes....1397
SPN 102 FMI 18 - Underboost....1400
Fault Overview....1400
Lamp Reaction....1400
Associated Faults....1400
Fault Facts....1400
Drive Cycle to Determine Fault Status....1400
Possible Causes....1400
IMT Sensor (Intake Manifold Temperature)....1405
Overview of IMT Sensor Group....1405
Overview....1405
SPN 105 FMI 2 - IMT signal Erratic, Intermittent, or Incorrect....1406
Fault Overview....1406
Lamp Reaction....1406
Associated Faults....1406
Fault Facts....1406
Drive Cycle to Determine Fault Status....1406
Possible Causes....1406
Pin-Point Tests (SPN 105 FMI 2)....1409
Tools Required....1409
SPN 105 FMI 3 - IMT signal Out of Range HIGH....1411
Fault Overview....1411
Lamp Reaction....1411
Associated Faults....1411
Fault Facts....1411
Drive Cycle to Determine Fault Status....1411
Possible Causes....1411
Pin-Point Tests (SPN 105 FMI 3)....1414
Tools Required....1414
SPN 105 FMI 4 - IMT signal Out of Range LOW....1417
Fault Overview....1417
Lamp Reaction....1417
Associated Faults....1417
Fault Facts....1417
Drive Cycle to Determine Fault Status....1417
Possible Causes....1417
Pin-Point Tests (SPN 105 FMI 4)....1419
Tools Required....1419
INJ (Injector) Circuits....1420
Overview of INJ Sensor Group....1420
Overview....1421
SPN 651 FMI 4 - Injector 1 open coil - short circuit....1423
Fault Overview....1423
Lamp Reaction....1423
Associated Faults....1423
Fault Facts....1423
Drive Cycle to Determine Fault Status....1423
Possible Causes....1423
Pin-Point Tests (SPN 651 FMI 4)....1426
Tools Required....1426
SPN 652 FMI 4 - Injector 2 open coil - short circuit....1427
Fault Overview....1427
Lamp Reaction....1427
Associated Faults....1427
Fault Facts....1427
Drive Cycle to Determine Fault Status....1427
Possible Causes....1427
Pin-Point Tests (SPN 652 FMI 4)....1430
Tools Required....1430
SPN 653 FMI 4 - Injector 3 open coil - short circuit....1431
Fault Overview....1431
Lamp Reaction....1431
Associated Faults....1431
Fault Facts....1431
Drive Cycle to Determine Fault Status....1431
Possible Causes....1431
Pin-Point Tests (SPN 653 FMI 4)....1434
Tools Required....1434
SPN 654 FMI 4 - Injector 4 open coil - short circuit....1435
Fault Overview....1435
Lamp Reaction....1435
Associated Faults....1435
Fault Facts....1435
Drive Cycle to Determine Fault Status....1435
Possible Causes....1435
Pin-Point Tests (SPN 654 FMI 4)....1438
Tools Required....1438
SPN 655 FMI 4 - Injector 5 open coil - short circuit....1439
Fault Overview....1439
Lamp Reaction....1439
Associated Faults....1439
Fault Facts....1439
Drive Cycle to Determine Fault Status....1439
Possible Causes....1439
Pin-Point Tests (SPN 655 FMI 4)....1442
Tools Required....1442
SPN 656 FMI 4 - Injector 6 open coil - short circuit....1443
Fault Overview....1443
Lamp Reaction....1443
Associated Faults....1443
Fault Facts....1443
Drive Cycle to Determine Fault Status....1443
Possible Causes....1443
Pin-Point Tests (SPN 656 FMI 4)....1446
Tools Required....1446
SPN 651 FMI 5 - Injector 1 open coil - open circuit....1447
Fault Overview....1447
Lamp Reaction....1447
Associated Faults....1447
Fault Facts....1447
Drive Cycle to Determine Fault Status....1447
Possible Causes....1447
Pin-Point Tests (SPN 651 FMI 5)....1450
Tools Required....1450
SPN 652 FMI 5 - Injector 2 open coil - open circuit....1454
Fault Overview....1454
Lamp Reaction....1454
Associated Faults....1454
Fault Facts....1454
Drive Cycle to Determine Fault Status....1454
Possible Causes....1454
Pin-Point Tests (SPN 652 FMI 5)....1457
Tools Required....1457
SPN 653 FMI 5 - Injector 3 open coil - open circuit....1461
Fault Overview....1461
Lamp Reaction....1461
Associated Faults....1461
Fault Facts....1461
Drive Cycle to Determine Fault Status....1461
Possible Causes....1461
Pin-Point Tests (SPN 653 FMI 5)....1464
Tools Required....1464
SPN 654 FMI 5 - Injector 4 open coil - open circuit....1468
Fault Overview....1468
Lamp Reaction....1468
Associated Faults....1468
Fault Facts....1468
Drive Cycle to Determine Fault Status....1468
Possible Causes....1468
Pin-Point Tests (SPN 654 FMI 5)....1471
Tools Required....1471
SPN 655 FMI 5 - Injector 5 open coil - open circuit....1475
Fault Overview....1475
Lamp Reaction....1475
Associated Faults....1475
Fault Facts....1475
Drive Cycle to Determine Fault Status....1475
Possible Causes....1475
Pin-Point Tests (SPN 655 FMI 5)....1478
Tools Required....1478
SPN 656 FMI 5 - Injector 6 open coil - open circuit....1482
Fault Overview....1482
Lamp Reaction....1482
Associated Faults....1482
Fault Facts....1482
Drive Cycle to Determine Fault Status....1482
Possible Causes....1482
Pin-Point Tests (SPN 656 FMI 5)....1485
Tools Required....1485
SPN 651 - 656 FMI 7 - Injector 1 (through 6) Spool Motion Compensation Max Authority Reached....1489
Fault Overview....1489
Lamp Reaction....1489
Associated Faults....1489
Fault Facts....1489
Drive Cycle to Determine Fault Status....1489
Possible Causes....1489
SPN 651 FMI 14 - Injector 1 Fuel quantity/timing error....1491
Fault Overview....1491
Lamp Reaction....1491
Associated Faults....1491
Fault Facts....1491
Drive Cycle to Determine Fault Status....1491
Possible Causes....1491
SPN 652 FMI 14 - Injector 2 Fuel quantity/timing error....1496
Fault Overview....1496
Lamp Reaction....1496
Associated Faults....1496
Fault Facts....1496
Drive Cycle to Determine Fault Status....1496
Possible Causes....1496
SPN 653 FMI 14 - Injector 3 Fuel quantity/timing error....1501
Fault Overview....1501
Lamp Reaction....1501
Associated Faults....1501
Fault Facts....1501
Drive Cycle to Determine Fault Status....1501
Possible Causes....1501
SPN 654 FMI 14 - Injector 4 Fuel quantity/timing error....1506
Fault Overview....1506
Lamp Reaction....1506
Associated Faults....1506
Fault Facts....1506
Drive Cycle to Determine Fault Status....1506
Possible Causes....1506
SPN 655 FMI 14 - Injector 5 Fuel quantity/timing error....1511
Fault Overview....1511
Lamp Reaction....1511
Associated Faults....1511
Fault Facts....1511
Drive Cycle to Determine Fault Status....1511
Possible Causes....1511
SPN 656 FMI 14 - Injector 6 Fuel quantity/timing error....1516
Fault Overview....1516
Lamp Reaction....1516
Associated Faults....1516
Fault Facts....1516
Drive Cycle to Determine Fault Status....1516
Possible Causes....1516
SPN 2797 FMI 6 - Injector Control Group 1 - short circuit (INJ 1, 2, 3)....1521
Fault Overview....1521
Lamp Reaction....1521
Associated Faults....1521
Fault Facts....1521
Drive Cycle to Determine Fault Status....1521
Possible Causes....1521
Pin-Point Tests (SPN 2797 FMI 6)....1530
Tools Required....1530
SPN 2798 FMI 6 - Injector Control Group 2 - short circuit (INJ 4, 5, 6)....1545
Fault Overview....1545
Lamp Reaction....1545
Associated Faults....1545
Fault Facts....1545
Drive Cycle to Determine Fault Status....1545
Possible Causes....1545
Pin-Point Tests (SPN 2798 FMI 6)....1554
Tools Required....1554
SPN 3055 FMI 2 - IPR Adaptation In-Range Fault....1569
Fault Overview....1569
Lamp Reaction....1569
Associated Faults....1569
Fault Facts....1569
Drive Cycle to Determine Fault Status....1569
Possible Causes....1569
SPN 3659 FMI 4 - Injector 1 close coil ? short circuit....1572
Fault Overview....1572
Lamp Reaction....1572
Associated Faults....1572
Fault Facts....1572
Drive Cycle to Determine Fault Status....1572
Possible Causes....1572
Pin-Point Tests (SPN 3659 FMI 4)....1575
Tools Required....1575
SPN 3660 FMI 4 - Injector 2 close coil ? short circuit....1576
Fault Overview....1576
Lamp Reaction....1576
Associated Faults....1576
Fault Facts....1576
Drive Cycle to Determine Fault Status....1576
Possible Causes....1576
Pin-Point Tests (SPN 3660 FMI 4)....1579
Tools Required....1579
SPN 3661 FMI 4 - Injector 3 close coil ? short circuit....1580
Fault Overview....1580
Lamp Reaction....1580
Associated Faults....1580
Fault Facts....1580
Drive Cycle to Determine Fault Status....1580
Possible Causes....1580
Pin-Point Tests (SPN 3661 FMI 4)....1583
Tools Required....1583
SPN 3662 FMI 4 - Injector 4 close coil ? short circuit....1584
Fault Overview....1584
Lamp Reaction....1584
Associated Faults....1584
Fault Facts....1584
Drive Cycle to Determine Fault Status....1584
Possible Causes....1584
Pin-Point Tests (SPN 3662 FMI 4)....1587
Tools Required....1587
SPN 3663 FMI 4 - Injector 5 close coil ? short circuit....1588
Fault Overview....1588
Lamp Reaction....1588
Associated Faults....1588
Fault Facts....1588
Drive Cycle to Determine Fault Status....1588
Possible Causes....1588
Pin-Point Tests (SPN 3663 FMI 4)....1591
Tools Required....1591
SPN 3664 FMI 4 - Injector 6 close coil ? short circuit....1592
Fault Overview....1592
Lamp Reaction....1592
Associated Faults....1592
Fault Facts....1592
Drive Cycle to Determine Fault Status....1592
Possible Causes....1592
Pin-Point Tests (SPN 3664 FMI 4)....1595
Tools Required....1595
SPN 3659 FMI 5 - Injector 1 close coil ? open circuit....1596
Fault Overview....1596
Lamp Reaction....1596
Associated Faults....1596
Fault Facts....1596
Drive Cycle to Determine Fault Status....1596
Possible Causes....1596
Pin-Point Tests (SPN 3659 FMI 5)....1599
Tools Required....1599
SPN 3660 FMI 5 - Injector 2 close coil ? open circuit....1603
Fault Overview....1603
Lamp Reaction....1603
Associated Faults....1603
Fault Facts....1603
Drive Cycle to Determine Fault Status....1603
Possible Causes....1603
Pin-Point Tests (SPN 3660 FMI 5)....1606
Tools Required....1606
SPN 3661 FMI 5 - Injector 3 close coil ? open circuit....1610
Fault Overview....1610
Lamp Reaction....1610
Associated Faults....1610
Fault Facts....1610
Drive Cycle to Determine Fault Status....1610
Possible Causes....1610
Pin-Point Tests (SPN 3661 FMI 5)....1613
Tools Required....1613
SPN 3662 FMI 5 - Injector 4 close coil ? open circuit....1617
Fault Overview....1617
Lamp Reaction....1617
Associated Faults....1617
Fault Facts....1617
Drive Cycle to Determine Fault Status....1617
Possible Causes....1617
Pin-Point Tests (SPN 3662 FMI 5)....1620
Tools Required....1620
SPN 3663 FMI 5 - Injector 5 close coil ? open circuit....1624
Fault Overview....1624
Lamp Reaction....1624
Associated Faults....1624
Fault Facts....1624
Drive Cycle to Determine Fault Status....1624
Possible Causes....1624
Pin-Point Tests (SPN 3663 FMI 5)....1627
Tools Required....1627
SPN 3664 FMI 5 - Injector 6 close coil ? open circuit....1631
Fault Overview....1631
Lamp Reaction....1631
Associated Faults....1631
Fault Facts....1631
Drive Cycle to Determine Fault Status....1631
Possible Causes....1631
Pin-Point Tests (SPN 3664 FMI 5)....1634
Tools Required....1634
SPN 4257 FMI 7 - Injector Coking Compensation Factor Reached Maximum Authority....1638
Fault Overview....1638
Lamp Reaction....1638
Associated Faults....1638
Fault Facts....1638
Drive Cycle to Determine Fault Status....1638
Possible Causes....1638
SPN 4257 FMI 16 - Multiple Injector High Flow fault....1640
Fault Overview....1640
Lamp Reaction....1640
Associated Faults....1640
Fault Facts....1640
Drive Cycle to Determine Fault Status....1640
Possible Causes....1640
SPN 4257 FMI 18 - Multiple Injector Low Flow fault....1643
Fault Overview....1643
Lamp Reaction....1643
Associated Faults....1643
Fault Facts....1643
Drive Cycle to Determine Fault Status....1643
Possible Causes....1643
IPR (Injection Pressure Regulator)....1646
Overview of IPR Sensor Group....1646
Overview....1646
SPN 679 FMI 3 - IPR Short to PWR....1647
Fault Overview....1647
Lamp Reaction....1647
Associated Faults....1647
Fault Facts....1647
Drive Cycle to Determine Fault Status....1647
Possible Causes....1647
Pin-Point Tests (SPN 679 FMI 3)....1649
Tools Required....1649
SPN 679 FMI 4 - IPR Open or short to GND....1651
Fault Overview....1651
Lamp Reaction....1651
Associated Faults....1651
Fault Facts....1651
Drive Cycle to Determine Fault Status....1651
Possible Causes....1651
Pin-Point Tests (SPN 679 FMI 4)....1654
Tools Required....1654
J1939 Data Link Communications....1658
Overview of J1939 Sensor Group....1658
Overview....1658
SPN 639 FMI 14 - J1939 Data Link Error (ECM unable to transmit)....1659
Fault Overview....1659
Lamp Reaction....1659
Associated Faults....1659
Fault Facts....1659
Drive Cycle to Determine Fault Status....1659
Possible Causes....1659
Pin-Point Tests....1662
Tools Required....1662
MAF Sensor (Mass Air Flow)....1664
Overview of MAF Sensor Group....1664
Overview....1664
SPN 132 FMI 0 - Engine Intake Air Mass Flow Rate High....1665
Fault Overview....1665
Lamp Reaction....1665
Associated Faults....1665
Fault Facts....1665
Drive Cycle to Determine Fault Status....1665
Possible Causes....1665
SPN 132 FMI 1 - Engine Intake Air Mass Flow Rate Low....1667
Fault Overview....1667
Lamp Reaction....1667
Associated Faults....1667
Fault Facts....1667
Drive Cycle to Determine Fault Status....1667
Possible Causes....1667
SPN 132 FMI 4 - MAF Frequency out of range....1669
Fault Overview....1669
Lamp Reaction....1669
Associated Faults....1669
Fault Facts....1669
Drive Cycle to Determine Fault Status....1669
Possible Causes....1669
Pin-Point Tests (SPN 132 FMI 4)....1671
Tools Required....1671
SPN 132 FMI 11 - MAF Sensor Calibration ? Insufficient number of data points....1673
Fault Overview....1673
Lamp Reaction....1673
Associated Faults....1673
Fault Facts....1673
Drive Cycle to Determine Fault Status....1673
Possible Causes....1673
SPN 132 FMI 13 - MAF Sensor Calibration Needed....1675
Fault Overview....1675
Lamp Reaction....1675
Associated Faults....1675
Fault Facts....1675
Drive Cycle to Determine Fault Status....1675
Possible Causes....1675
SPN 132 FMI 14 - MAF Sensor Calibration Failed....1677
Fault Overview....1677
Lamp Reaction....1677
Associated Faults....1677
Fault Facts....1677
Drive Cycle to Determine Fault Status....1677
Possible Causes....1677
SPN 132 FMI 31 - MAF Frequency Not Detected....1679
Fault Overview....1679
Lamp Reaction....1679
Associated Faults....1679
Fault Facts....1679
Drive Cycle to Determine Fault Status....1679
Possible Causes....1679
Pin-Point Tests (SPN 132 FMI 31)....1684
Tools Required....1684
SPN 172 FMI 2 - IAT Signal Erratic, Intermittent, or Incorrect....1692
Fault Overview....1692
Lamp Reaction....1692
Associated Faults....1692
Fault Facts....1692
Drive Cycle to Determine Fault Status....1692
Possible Causes....1692
Pin-Point Tests (SPN 172 FMI 2)....1695
Tools Required....1695
SPN 172 FMI 3 - IAT Signal Out of Range HIGH....1698
Fault Overview....1698
Lamp Reaction....1698
Associated Faults....1698
Fault Facts....1698
Drive Cycle to Determine Fault Status....1698
Possible Causes....1698
Pin-Point Tests (SPN 172 FMI 3)....1701
Tools Required....1701
SPN 172 FMI 4 - IAT Signal Out of Range LOW....1705
Fault Overview....1705
Lamp Reaction....1705
Associated Faults....1705
Fault Facts....1705
Drive Cycle to Determine Fault Status....1705
Possible Causes....1705
Pin-Point Tests (SPN 172 FMI 4)....1707
Tools Required....1707
NOx (Nitrogen Oxides) Sensor Module....1708
Overview of NOx Sensor Group....1708
Overview....1708
SPN 3216 FMI 4 - NOxIN signal Out of Range LOW....1712
Fault Overview....1712
Lamp Reaction....1712
Associated Faults....1712
Fault Facts....1712
Drive Cycle to Determine Fault Status....1712
Possible Causes....1712
SPN 3216 FMI 10 - NOxIN signal abnormal rate of change....1714
Fault Overview....1714
Lamp Reaction....1714
Associated Faults....1714
Fault Facts....1714
Drive Cycle to Determine Fault Status....1714
Possible Causes....1714
SPN 3216 FMI 13 - NOx IN Out of Calibration....1716
Fault Overview....1716
Lamp Reaction....1716
Associated Faults....1716
Fault Facts....1716
Drive Cycle....1716
Possible Causes....1716
SPN 3216 FMI 19 - NOx IN not detected on J1939....1718
Fault Overview....1718
Lamp Reaction....1718
Associated Faults....1718
Fault Facts....1718
Drive Cycle to Determine Fault Status....1718
Possible Causes....1718
Pin-Point Tests (SPN 3216 FMI 19)....1723
Tools Required....1723
SPN 3216 FMI 20 - NOxIN signal drifted HIGH....1731
Fault Overview....1731
Lamp Reaction....1731
Associated Faults....1731
Drive Cycle to Determine Fault Status....1731
Possible Causes....1731
SPN 3216 FMI 21 - NOxIN signal drifted LOW....1733
Fault Overview....1733
Lamp Reaction....1733
Associated Faults....1733
Fault Facts....1733
Drive Cycle to Determine Fault Status....1733
Possible Causes....1733
SPN 3218 FMI 2 - NOxIN power supply signal erratic, intermittent or incorrect....1735
Fault Overview....1735
Lamp Reaction....1735
Associated Faults....1735
Drive Cycle to Determine Fault Status....1735
Pin-Point Tests (SPN 3218 FMI 2)....1738
Tools Required....1738
SPN 3226 FMI 2 - NOx OUT Signal Erratic, Intermittent, or Incorrect ....1741
Fault Overview....1741
Lamp Reaction....1741
Associated Faults....1741
Fault Facts....1741
Drive Cycle to Determine Fault Status....1741
Possible Causes....1741
Pin-Point Tests SPN 3226 FMI 2....1744
Tools Required....1744
SPN 3226 FMI 4 - NOxOUT signal Out of Range LOW....1747
Fault Overview....1747
Lamp Reaction....1747
Associated Faults....1747
Fault Facts....1747
Drive Cycle to Determine Fault Status....1747
Possible Causes....1747
SPN 3226 FMI 10 - NOx OUT Signal Abnormal Rate of Change....1749
Fault Overview....1749
Lamp Reaction....1749
Associated Faults....1749
Fault Facts....1749
Drive Cycle to Determine Fault Status....1749
Possible Causes....1749
SPN 3226 FMI 13 - NOxOUT Out of Calibration....1751
Fault Overview....1751
Lamp Reaction....1751
Associated Faults....1751
Fault Facts....1751
Drive Cycle to Determine Fault Status....1751
Possible Causes....1751
SPN 3226 FMI 19 - NOxOUT not detected on J1939....1753
Fault Overview....1753
Lamp Reaction....1753
Associated Faults....1753
Fault Facts....1753
Drive Cycle to Determine Fault Status....1753
Possible Causes....1753
Pin-Point Tests (SPN 3226 FMI 19)....1757
Tools Required....1757
SPN 3226 FMI 20 - NOxOUT signal drifted HIGH....1764
Fault Overview....1764
Lamp Reaction....1764
Associated Faults....1764
Fault Facts....1764
Drive Cycle to Determine Fault Status....1764
Possible Causes....1764
SPN 3226 FMI 21 - NOxOUT signal drifted LOW....1766
Fault Overview....1766
Lamp Reaction....1766
Associated Faults....1766
Fault Facts....1766
Drive Cycle to Determine Fault Status....1766
Possible Causes....1766
SPN 3228 FMI 2 - NOxOUT power supply signal erratic, intermittent or incorrect....1768
Fault Overview....1768
Lamp Reaction....1768
Associated Faults....1768
Fault Facts....1768
Drive Cycle to Determine Fault Status....1768
Possible Causes....1768
Pin-Point Tests (SPN 3228 FMI 2)....1771
Tools Required....1771
SPN 5024 FMI 10 - NOxIN Sensor Heater abnormal rate of change....1774
Fault Overview....1774
Lamp Reaction....1774
Associated Faults....1774
Fault Facts....1774
Drive Cycle to Determine Fault Status....1774
Possible Causes....1774
Pin-Point Tests (SPN 5024 FMI 10)....1777
Tools Required....1777
SPN 5031 FMI 10 - NOxOUT Sensor Heater not reading correctly....1780
Fault Overview....1780
Lamp Reaction....1780
Associated Faults....1780
Fault Facts....1780
Drive Cycle to Determine Fault Status....1780
Possible Causes....1780
Pin-Point Tests (SPN 5031 FMI 10)....1783
Tools Required....1783
RAPP (Remote APP) Sensor....1786
Overview of RAPP Sensor Group....1786
Overview....1786
SPN 974 FMI 3 - Remote APP signal Out of Range HIGH....1787
Fault Overview....1787
Lamp Reaction....1787
Associated Faults....1787
Fault Facts....1787
Drive Cycle to Determine Fault Status....1787
Possible Causes....1787
Pin-Point Tests....1789
Tools Required....1789
SCR (Temperature Sensor Module)....1791
Overview of SCR Sensor Group....1791
Overview....1791
SPN 3061 FMI 31 - CSER Exhaust warm up time fault....1794
Fault Overview....1794
Lamp Reaction....1794
Associated Faults....1794
Fault Facts....1794
Drive Cycle to Determine Fault Status....1794
Possible Causes....1794
SPN 4364 FMI 18- Low NOx Conversion Detected....1797
Fault Overview....1797
Lamp Reaction....1797
Associated Faults....1797
Fault Facts....1797
Drive Cycle to Determine Fault Status....1797
Possible Causes....1797
SPN 4792 FMI 7 - SCR Catalyst System - Mechanical system not responding or out of adjustment....1800
Fault Overview....1800
Lamp Reaction....1800
Associated Faults....1800
Fault Facts....1800
Drive Cycle to Determine Fault Status....1800
Possible Causes....1800
SPN 4792 FMI 14 - SCR Temperature Module (Incorrect Part)....1802
Fault Overview....1802
Lamp Reaction....1802
Associated Faults....1802
Fault Facts....1802
Drive Cycle to Determine Fault Status....1802
Possible Causes....1802
SPN 4794 FMI 31 - SCR Catalyst System Missing....1804
Fault Overview....1804
Lamp Reaction....1804
Associated Faults....1804
Fault Facts....1804
Drive Cycle to Determine Fault Status....1804
Possible Causes....1804
SPN 5743 FMI 3 - SCR Thermocouple Controller Out of Range HIGH....1806
Fault Overview....1806
Lamp Reaction....1806
Associated Faults....1806
Fault Facts....1806
Drive Cycle to Determine Fault Status....1806
Possible Causes....1806
Pin-Point Tests (SPN 5743 FMI 3)....1808
Tools Required....1808
SPN 5743 FMI 4 - SCR Thermocouple Controller Out of Range LOW....1810
Fault Overview....1810
Lamp Reaction....1810
Associated Faults....1810
Fault Facts....1810
Drive Cycle to Determine Fault Status....1810
Possible Causes....1810
Pin-Point Tests (SPN 5743 FMI 4)....1813
Tools Required....1813
SPN 5743 FMI 11 - SCR Thermocouple Controller signal erratic, intermittent, or incorrect....1816
Fault Overview....1816
Lamp Reaction....1816
Associated Faults....1816
Fault Facts....1816
Drive Cycle to Determine Fault Status....1816
Possible Causes....1816
Pin-Point Tests (SPN 5743 FMI 11)....1819
Tools Required....1819
SPN 5743 FMI 12 - SCR Temperature sensor module internal error....1822
Fault Overview....1822
Lamp Reaction....1822
Associated Faults....1822
Fault Facts....1822
Drive Cycle to Determine Fault Status....1822
Possible Causes....1822
SPN 5743 FMI 16 - SCR Thermocouple Controller above Maximum Temperature....1824
Fault Overview....1824
Lamp Reaction....1824
Associated Faults....1824
Fault Facts....1824
Drive Cycle to Determine Fault Status....1824
Possible Causes....1824
SPN 5743 FMI 19 - SCR Temperature module not detect J1939....1826
Fault Overview....1826
Lamp Reaction....1826
Associated Faults....1826
Fault Facts....1826
Drive Cycle to Determine Fault Status....1826
Possible Causes....1826
Pin-Point Tests (SPN 5743 FMI 19)....1831
Tools Required....1831
SCRIT (Selective Catalyst Reduction Intake Temperature) Sensor....1839
Overview of SCRIT Sensor Group....1839
Overview....1839
SPN 4360 FMI 0 - SCRIT above Critical Temperature....1840
Fault Overview....1840
Lamp Reaction....1840
Associated Faults....1840
Fault Facts....1840
Drive Cycle to Determine Fault Status....1840
Possible Causes....1840
SPN 4360 FMI 2- SCRIT signal erratic, intermittent or incorrect....1843
Fault Overview....1843
Lamp Reaction....1843
Associated Faults....1843
Fault Facts....1843
Drive Cycle to Determine Fault Status....1843
Possible Causes....1843
SPN 4360 FMI 3 - SCRIT Signal Out of Range HIGH....1845
Fault Overview....1845
Lamp Reaction....1845
Associated Faults....1845
Fault Facts....1845
Drive Cycle to Determine Fault Status....1845
Possible Causes....1845
SPN 4360 FMI 4 - SCRIT Signal Out of Range LOW....1847
Fault Overview....1847
Lamp Reaction....1847
Associated Faults....1847
Fault Facts....1847
Drive Cycle to Determine Fault Status....1847
Possible Causes....1847
SPN 4360 FMI 15 - SCRIT above Warning Temperature....1849
Fault Overview....1849
Lamp Reaction....1849
Associated Faults....1849
Fault Facts....1849
Drive Cycle to Determine Fault Status....1849
Possible Causes....1849
SPN 4360 FMI 16 - SCRIT above Maximum Temperature....1852
Fault Overview....1852
Lamp Reaction....1852
Associated Faults....1852
Fault Fact....1852
Drive Cycle to Determine Fault Status....1852
Possible Causes....1852
SCROT (Selective Catalyst Reduction Outlet Temperature) Sensor....1855
Overview of SCROT Sensor Group....1855
Overview....1855
SPN 4363 FMI 0 - SCROT above Critical Temperature....1856
Fault Overview....1856
Lamp Reaction....1856
Associated Faults....1856
Fault Facts....1856
Drive Cycle to Determine Fault Status....1856
Possible Causes....1856
SPN 4363 FMI 2 - SCROT signal erratic, intermittent or incorrect....1859
Fault Overview....1859
Lamp Reaction....1859
Associated Faults....1859
Fault Facts....1859
Drive Cycle to Determine Fault Status....1859
Possible Causes....1859
SPN 4363 FMI 3 - SCROT signal Out of Range HIGH....1861
Fault Overview....1861
Lamp Reaction....1861
Associated Faults....1861
Fault Facts....1861
Drive Cycle to Determine Fault Status....1861
Possible Causes....1861
SPN 4363 FMI 4 - SCROT signal Out of Range LOW....1863
Fault Overview....1863
Lamp Reaction....1863
Associated Faults....1863
Fault Facts....1863
Drive Cycle to Determine Fault Status....1863
Possible Causes....1863
SPN 4363 FMI 15 - SCROT above Warning Temperature....1865
Fault Overview....1865
Lamp Reaction....1865
Associated Faults....1865
Fault Facts....1865
Drive Cycle to Determine Fault Status....1865
Possible Causes....1865
SPN 4363 FMI 16 - SCROT above Maximum Temperature....1868
Fault Overview....1868
Lamp Reaction....1868
Associated Faults....1868
Fault Facts....1868
Drive Cycle to Determine Fault Status....1868
Possible Causes....1868
TC2CIT (Turbocharger 2 Compressor Intake Temperature)....1871
Overview of TC2CIT Sensor Group....1871
Overview....1871
SPN 1173 FMI 2 - TC2CIT signal erratic, intermittent, or incorrect ....1872
Fault Overview....1872
Lamp Reaction....1872
Associated Faults....1872
Fault Facts....1872
Drive Cycle to Determine Fault Status....1872
Possible Causes....1872
Pin-Point Tests (SPN 1173 FMI 2)....1875
Tools Required....1875
SPN 1173 FMI 3 - TC2CIT Signal Out of Range HIGH....1877
Fault Overview....1877
Lamp Reaction....1877
Associated Faults....1877
Fault Facts....1877
Drive Cycle to Determine Fault Status....1877
Possible Causes....1877
Pin-Point Tests (SPN 1173 FMI 3)....1880
Tools Required....1880
SPN 1173 FMI 4 - TC2CIT Signal Out of Range LOW....1883
Fault Overview....1883
Lamp Reaction....1883
Associated Faults....1883
Fault Facts....1883
Drive Cycle to Determine Fault Status....1883
Possible Causes....1883
Pin-Point Tests (SPN 1173 FMI 4)....1885
Tools Required....1885
SPN 1173 FMI 16 - TC2CIT signal above desired (Low Pressure CAC Interstage under cooling)....1886
Fault Overview....1886
Lamp Reaction....1886
Associated Faults....1886
Fault Facts....1886
Drive Cycle to Determine Fault Status....1886
Possible Causes....1886
TC2WG (Turbocharger 2 Wastegate Position)....1889
Overview of TC2WG Group....1889
Overview....1889
SPN 1189 FMI 3 - TC2WC short to PWR....1890
Fault Overview....1890
Lamp Reaction....1890
Associated Faults....1890
Fault Facts....1890
Drive Cycle to Determine Fault Status....1890
Possible Causes....1890
Pin-Point Tests SPN 1189 FMI 3....1892
Tools Required....1892
SPN 1189 FMI 4 - TC2WC Open or short to GND....1894
Fault Overview....1894
Lamp Reaction....1894
Associated Faults....1894
Fault Facts....1894
Drive Cycle to Determine Fault Status....1894
Possible Causes....1894
Pin-Point Tests (SPN 1189 FMI 4)....1897
Tools Required....1897
TOSS (Transmission Output Shaft Speed) Sensor....1901
Overview of TOSS Sensor Group....1901
Overview....1901
SPN 191 FMI 3 - TOSS/VSS signal out of range HIGH....1903
Fault Overview....1903
Lamp Reaction....1903
Associated Faults....1903
Fault Facts....1903
Drive Cycle to Determine Fault Status....1903
Possible Causes....1903
Pin-Point Tests (SPN 191 FMI 3)....1905
Tools Required....1905
SPN 191 FMI 4 - TOSS/VSS signal out of range LOW....1906
Fault Overview....1906
Lamp Reaction....1906
Associated Faults....1906
Fault Facts....1906
Drive Cycle to Determine Fault Status....1906
Possible Causes....1906
Pin-Point Tests (SPN 191 FMI 4)....1908
Tools Required....1908
SPN 191 FMI 5 - TOSS/VSS Open Circuit fault....1909
Fault Overview....1909
Lamp Reaction....1909
Associated Faults....1909
Fault Facts....1909
Drive Cycle to Determine Fault Status....1909
Possible Causes....1909
Pin-Point Tests (SPN 191 FMI 5)....1912
Tools Required....1912
SPN 191 FMI 14 - TOSS/VSS Error invalid signal....1913
Fault Overview....1913
Lamp Reaction....1913
Associated Faults....1913
Fault Facts....1913
Drive Cycle to Determine Fault Status....1913
Possible Causes....1913
VREF (Voltage Reference)....1915
Overview of VREF Sensor Group....1915
Overview....1915
SPN 3509 FMI 3 - VREF 1 voltage above maximum....1916
Fault Overview....1916
Lamp Reaction....1916
Associated Faults....1916
Fault Facts....1916
Drive Cycle to Determine Fault Status....1916
Possible Causes....1916
Pin-Point Tests (SPN 3509 FMI 3)....1919
Tools Required....1919
SPN 3509 FMI 4 - VREF 1 voltage below minimum....1925
Fault Overview....1925
Lamp Reaction....1925
Associated Faults....1925
Fault Facts....1925
Drive Cycle to Determine Fault Status....1925
Possible Causes....1925
Pin-Point Tests (SPN 3509 FMI 4)....1929
Tools Required....1929
SPN 3510 FMI 3 - VREF 2 voltage above maximum....1941
Fault Overview....1941
Lamp Reaction....1941
Associated Faults....1941
Fault Facts....1941
Drive Cycle to Determine Fault Status....1941
Possible Causes....1941
SPN 3510 FMI 4 - VREF 2 voltage below minimum....1943
Fault Overview....1943
Lamp Reaction....1943
Associated Faults....1943
Fault Facts....1943
Drive Cycle to Determine Fault Status....1943
Possible Causes....1943
Pin-Point Tests (SPN 3510 FMI 4)....1945
Tools Required....1945
SPN 3511 FMI 3 - VREF 3 voltage above maximum....1948
Fault Overview....1948
Lamp Reaction....1948
Associated Faults....1948
Fault Facts....1948
Drive Cycle to Determine Fault Status....1948
Possible Causes....1948
Pin-Point Tests (SPN 3511 FMI 3)....1950
Tools Required....1950
SPN 3511 FMI 4 - VREF 3 voltage below minimum....1952
Fault Overview....1952
Lamp Reaction....1952
Associated Faults....1952
Fault Facts....1952
Drive Cycle to Determine Fault Status....1952
Possible Causes....1952
Pin-Point Tests (SPN 3511 FMI 4)....1955
Tools Required....1955
SPN 5125 FMI 14 - VREF 7 voltage above or below normal....1960
Fault Overview....1960
Lamp Reaction....1960
Associated Faults....1960
Fault Facts....1960
Drive Cycle to Determine Fault Status....1960
Possible Causes....1960
SPN 5126 FMI 14 - VREF 8 voltage above or below normal....1962
Fault Overview....1962
Lamp Reaction....1962
Associated Faults....1962
Fault Facts....1962
Drive Cycle to Determine Fault Status....1962
Possible Causes....1962
Pin-Point Tests (SPN 5126 FMI 14)....1964
Tools Required....1964
SPN 5127 FMI 14 - VREF 9 voltage above or below normal....1965
Fault Overview....1965
Lamp Reaction....1965
Associated Faults....1965
Fault Facts....1965
Drive Cycle to Determine Fault Status....1965
Possible Causes....1965
Pin-Point Tests (SPN 5126 FMI 14)....1968
Tools Required....1968
WIF Sensor (Water In Fuel)....1970
Overview of WIF Sensor Group....1970
Overview....1970
SPN 4192 FMI 3 - WIF signal Out of Range HIGH....1971
Fault Overview....1971
Lamp Reaction....1971
Associated Faults....1971
Fault Facts....1971
Drive Cycle to Determine Fault Status....1971
Possible Causes....1971
Pin-Point Tests SPN 4192 FMI 3....1973
Tools Required....1973
SPN 4192 FMI 4 - WIF signal Out of Range LOW....1975
Fault Overview....1975
Lamp Reaction....1975
Associated Faults....1975
Fault Facts....1975
Drive Cycle to Determine Fault Status....1975
Possible Causes....1975
Pin-Point Tests SPN 4192 FMI 4....1977
Tools Required....1977
SPN 4192 FMI 5 - WIF signal Open or Short to PWR....1978
Fault Overview....1978
Lamp Reaction....1978
Associated Faults....1978
Fault Facts....1978
Drive Cycle to Determine Fault Status....1978
Possible Causes....1978
Pin-Point Tests SPN 4192 FMI 5....1981
Tools Required....1981
SPN 4192 FMI 31 - Water in Fuel Detected....1984
Fault Overview....1984
Lamp Reaction....1984
Associated Faults....1984
Fault Facts....1984
Drive Cycle to Determine Fault Status....1984
Possible Causes....1984
Table of Contents....1986
ServiceMaxx? Software Procedures....1990
ServiceMaxx? Connection and Data Recording....1990
Overview....1990
Engine Auto-Detection....1990
Connection (Sniffer)....1990
Tools Required....1990
Equipment Condition....1990
Test Setup....1991
Test Procedure....1992
Snapshot Recording Procedure:....1992
Snapshot Playback Procedure....1993
Diagnostic Trouble Code Overview....1995
DTC Type:....1995
Pending DTC....1995
Active DTC....1995
Healing DTC....1995
Previously Active DTC....1995
DTC Count....1995
Freeze Frame....1995
Check for DTCs....1996
Procedure:....1996
Session Files....1997
Overview....1997
Hot Run Sensor Comparison Test....1999
Purpose....1999
Tools Required....1999
Obtain Vehicle Health Report....2001
Overview....2001
Tools Required....2001
Equipment Condition....2001
Test Setup....2001
Test Procedure....2001
Expected Outcome....2001
Follow-On Procedure....2001
Programmable Features....2002
Overview....2002
Tool Required....2002
Equipment Condition....2002
Test Setup....2003
Test Procedure....2004
Expected Outcome....2006
Follow-On Procedure....2006
Record Snapshot of KOEO Data....2007
Overview....2007
Tools Required....2007
Equipment Condition....2007
Test Setup....2007
Test Procedure....2007
Expected Outcome....2007
Follow-On Procedure....2007
Injector Coil End of Motion (CEOM) Reset Procedure....2008
Overview....2008
Tools Required....2008
Equipment Condition....2008
Test Setup....2009
Test Procedure....2010
Fuel Pressure Adaptation Reset....2011
Overview....2011
Tools Required....2011
Equipment Condition....2011
Test Setup....2012
Test Procedure....2012
Follow-On Procedure....2013
KOEO DOC / DPF Replacement / Reset Procedure....2014
Overview....2014
Tools Required....2014
Equipment Condition....2015
Test Setup....2015
Test Procedure....2015
Intermittent or Inactive Fault Diagnostic Procedure....2017
Overview....2017
Tools Required....2017
Equipment Condition....2017
Test Setup....2017
Test Procedure....2017
Expected Outcome....2017
Follow-On Procedure....2017
Connecting EST with ServiceMaxx? Software to Engine....2018
Interface Device Selection....2018
Connecting ServiceMaxx? Software....2021
Pinpoint Diagnostic Graphic Legend....2022
Service Bay Tests....2030
Engine Off Tests....2030
KOEO Standard Test....2030
Overview....2030
Tools Required....2030
Equipment Condition....2030
Test Setup....2031
Test Procedure....2032
Expected Outcome....2033
Follow-On Procedure....2033
KOEO Low to High Idle Test....2034
Overview....2034
Tools Required....2034
Equipment Condition....2034
Test Setup....2034
Test Procedure....2035
Expected Outcome....2037
Follow-On Procedure....2037
KOEO Output State High or Low....2038
Overview....2038
Actuators that cycle during this test:....2038
Tools Required....2038
Equipment Condition....2038
Test Setup....2038
Test Procedure....2038
Expected Outcome....2039
Follow-On Procedure....2039
Continuous Monitor....2040
Overview....2040
Position Sensor Voltages are Monitored:....2041
Pressure Sensor Voltages are Monitored:....2041
Temperature Sensor Voltages are Monitored:....2041
Other Voltage Signals Monitored:....2041
Tools Required....2041
Equipment Condition....2041
Test Setup....2042
Test Procedure....2042
Follow-on Procedure....2043
KOEO DEF Tank Heater Test....2044
Overview....2044
Tools Required....2044
Equipment Conditions....2044
Test Setup....2045
Test Procedure....2046
Expected Outcome....2046
Follow-On Procedure....2046
KOEO Injector Test....2047
Overview....2047
Tools Required....2047
Equipment Condition....2047
Test Setup....2047
Test Procedure....2047
Expected Outcome....2049
Follow-on Procedure....2049
KOEO DCU Actuator Test ? Actuator Output High and Low Diagnostics....2050
Overview....2050
Tools Required....2050
Test Setup....2051
Test Procedure....2051
Expected Outcome....2052
Follow-On Procedure....2052
KOEO DEF System Leak Test....2053
Overview....2053
Tools Required....2053
Equipment Condition....2053
Test Setup....2053
Test Procedure....2053
Expected Outcome....2054
Follow-On Procedure....2054
KOEO DEF Line Heater Test....2055
Overview....2055
Tools Required....2055
Equipment Condition....2055
Test Setup....2055
Test Procedure....2055
Expected Outcome....2056
Follow-On Procedure....2056
KOEO DEF Reverting Control Valve Test....2057
Overview....2057
Tools Required....2057
Test Setup....2057
Test Procedure....2058
Expected Outcome....2058
Follow-On Procedure....2058
KOEO DEF Supply Pump Override Test....2059
Overview....2059
Tools Required....2059
Equipment Conditions....2059
Test Setup....2059
Test Procedure....2059
Expected Outcome....2060
Follow-On Procedure....2060
Relative Compression Test....2061
Overview....2061
Tools Required....2061
Test Setup....2061
Test Procedure....2062
Expected Outcome....2063
Follow-On Procedure....2063
SCR Faults Reset Request Procedure....2064
Overview....2064
Tools Required....2064
Equipment Condition....2064
Test Setup....2064
Test Procedure....2064
Expected Outcome....2065
Follow-On Procedure....2065
Engine Cranking Test....2066
Overview....2066
Tools Required....2066
Equipment Condition....2066
Test Setup....2066
Procedure....2067
Expected Outcome....2068
Follow-on Procedure....2068
Engine Running Tests....2069
Air Management Test....2069
Overview....2069
Tools Required....2069
Equipment Conditions....2069
Test Setup....2070
Test Procedure....2070
Expected Outcome....2070
Follow-On Procedure....2070
Air Management System Graph (GOOD)....2071
Overview....2071
Tools Required....2071
Equipment Condition....2071
Test Setup....2071
Test Procedure....2072
Expected Outcome....2072
Follow-On Procedure....2072
Air Management System Graph (BAD) ....2073
Overview....2073
Tools Required....2073
Equipment Condition....2073
Test Setup....2073
Test Procedure....2074
Expected Outcome....2074
Follow-On Procedure....2074
KOER Standard Test....2075
Overview....2075
Tools Required....2075
Equipment Conditions....2075
Test Setup....2076
Test Procedure....2077
Expected Outcome....2077
Follow-On Procedure....2077
KOER Cylinder Cutout Test....2078
Overview....2078
Tools Required....2078
Equipment Condition....2078
Test Setup....2078
Test Procedure....2079
Expected Outcome....2080
Follow-on Procedure....2080
KOER DSI System Test....2081
Overview....2081
Tools Required....2081
Equipment Conditions....2082
Test Setup....2082
Test Procedure....2082
Expected Outcome....2083
Follow-On Procedure....2083
KOER DSI Deaeration Procedure....2084
Overview....2084
Tools Required....2084
Equipment Condition....2084
Test Setup....2085
Test Procedure....2086
Expected Outcome....2086
Follow-On Procedure....2086
DPF Regeneration Procedure....2087
Overview....2087
Tools Required....2087
Equipment Condition....2087
Test Setup....2088
Test Procedure....2089
Expected Outcome....2090
Follow-On Procedure....2090
Connect Cylinder Performance Analyzer (CPA) Tool....2091
Overview....2091
Tools Required....2091
Equipment Condition....2091
Test Setup....2092
Test Procedure....2093
Expected Outcome....2094
Follow-on Procedure....2094
CPA Cold Idle Test....2095
Overview....2095
Tools Required....2095
Equipment Condition....2095
Test Setup....2095
Test Procedure....2098
Expected Outcome....2099
Follow-on Procedure....2099
CPA Signal Check....2100
Overview....2100
Tools Required....2100
Equipment Condition....2100
Test Setup....2100
Test Procedure....2102
Expected Outcome....2105
Follow-On Procedure....2105
CPA Hot Idle Test....2106
Overview....2106
Tools Required....2106
Equipment Condition....2106
Test Setup....2106
Test Procedure....2109
Expected Outcome....2110
Follow-On Procedure....2110
CPA Road Test....2111
Overview....2111
Tools Required....2111
Equipment Condition....2111
Test Setup....2111
Test Procedure....2114
Expected Outcome....2115
Follow-On Procedure....2115
CPA Advanced Testing....2116
Overview....2116
Tools Required....2116
Equipment Condition....2116
Test Setup....2116
Test Procedure....2118
Expected Outcome....2120
Follow-on Procedure....2120
CPA High-Pressure Oil Pump (HPOP) Test....2121
Overview....2121
Tools Required....2121
Equipment Condition....2121
Test Setup....2121
Test Procedure....2123
Expected Outcome....2125
Follow-on Procedure....2125
Record Snapshot of Engine Running Data....2126
Overview....2126
Tools Required....2126
Equipment Condition....2126
Test Setup....2126
Test Procedure....2127
Expected Outcome....2129
Follow-On Procedure....2129
Road Test....2130
0 to 60 MPH Test....2130
Overview....2130
Tools Required....2130
Equipment Condition....2130
Test Setup....2130
Test Procedure....2130
Expected Outcome....2133
Follow-on Procedure....2133
0 to 60 MPH ICP and ICPD Graph ....2134
Overview....2134
Tools Required....2134
Equipment Condition....2134
Test Setup....2134
Test Procedure....2135
Expected Outcome....2135
Follow-On Procedure....2135
0 to 60 MPH, RPM, Load, IMP, EBP, and APP1 Graph....2136
Overview....2136
Tools Required....2136
Equipment Condition....2136
Test Setup....2136
Test Procedure....2137
Expected Outcome....2137
Follow-On Procedure....2138
Normal Exhaust Gas Temperature Graph....2139
Overview....2139
Tools Required....2139
Equipment Condition....2139
Test Setup....2139
Test Procedure....2140
Expected Outcome....2140
Follow-On Procedure....2141
Erratic Exhaust Gas Temperatures Graph....2142
Overview....2142
Tools Required....2142
Equipment Condition....2142
Test Setup....2142
Test Procedure....2143
Expected Outcome ....2143
Follow-On Procedure....2144
Low Exhaust Gas Temperatures Graph....2145
Overview....2145
Tools Required....2145
Equipment Condition....2145
Test Setup....2145
Test Procedure....2146
Expected Outcome....2146
Follow-On Procedure....2147
Air Control Valve (ACV) Test....2148
Exhaust Back Pressure Valve (EBPV) Test....2148
Overview....2148
Tools Required....2148
Equipment Condition....2148
Test Setup....2148
Test Procedure....2148
Expected Outcome....2149
Follow-on Procedure....2149
Boost Control System Test....2150
Overview....2150
Tools Required....2150
Equipment Condition....2150
Test Setup....2150
Test Procedure....2151
Expected Outcome....2152
Follow-On Procedure....2152
Turbocharger 2 Wastegate Position (TC2WG) Operational Test....2153
Overview....2153
Tools Required....2153
Equipment Condition....2153
Test Setup....2153
Test Procedure....2155
Expected Outcome....2155
Follow-On Procedure....2156
Turbocharger 2 Wastegate Position (TC2WG) Solenoid Test....2157
Overview....2157
Tools Required....2157
Equipment Condition....2157
Test Setup....2157
Test Procedure....2157
Expected Outcome....2157
Follow-On Procedure....2157
Turbocharger 2 Wastegate Position (TC2WG) Isolated Actuator Test....2158
Overview....2158
Tools Required....2158
Equipment Condition....2158
Test Setup....2159
Test Procedure....2160
Expected Outcome....2161
Follow-On Procedure....2161
KOER MAF Sensor Calibrations....2162
Overview....2162
Tools Required....2162
Equipment Condition....2162
MAF Calibration Pre-Checks....2162
Test Setup....2163
Test Procedure....2164
Expected Outcome....2164
Follow-On Procedure....2164
Exhaust Gas Recirculation Valve (EGRV) Operational Test....2165
Overview....2165
Tool Required....2165
Equipment Condition....2165
Test Setup....2165
Test Procedure....2165
Expected Outcome....2166
Follow-On Maintenance....2166
Low-Pressure Fuel System Tests....2167
Fuel Delivery Pressure (FDP) Test....2167
Overview....2167
Tools Required....2167
Equipment Condition....2167
Test Setup....2168
Test Procedure....2169
Expected Outcome....2169
Follow-On Procedure....2169
Fuel Pump Voltage Test....2170
Overview....2170
Tools Required....2170
Equipment Condition....2170
Test Setup....2170
Test Procedure....2171
Expected Outcome....2172
Follow-On Procedure....2172
Clean Fuel Source Test....2173
Overview....2173
Tools Required....2173
Equipment Condition....2173
Test Setup....2173
Test Procedure....2175
Expected Outcome....2175
Follow-on Procedure....2176
Intake Air Heater (IAH) Tests....2177
Intake Air Heater System Test....2177
Overview....2177
Tools Required....2177
Equipment Condition....2177
Test Setup....2177
Test Procedure....2178
Expected Outcome....2178
Follow-on Procedure....2178
Intake Air Heater (IAH) Current Draw Test....2179
Overview....2179
Tools Required....2179
Equipment Condition....2179
Test Setup....2179
Test Procedure....2180
Expected Outcome....2181
Intake Air Heater (IAH) Relay Test....2182
Overview....2182
Tools Required....2182
Equipment Condition....2182
Test Setup....2182
Test Procedure....2183
Expected Outcome....2184
Follow-On Procedure....2184
High-Pressure Charge Air Cooler (HPCAC) Pressure Test....2185
Overview....2185
Tools Required....2185
Equipment Condition....2185
Test Setup....2186
Test Procedure....2187
Expected Outcome....2191
Follow-On Procedure....2191
Interstage Cooler (ISC) Pressure Test....2192
Overview....2192
Tools Required....2192
Equipment Condition....2192
Test Setup....2193
Test Procedure....2193
Expected Outcome....2194
Follow-On Procedure....2194
Crankcase Pressure Test....2195
Overview....2195
Tools Required....2195
Equipment Condition....2195
Test Setup....2195
Test Procedure....2198
Expected Outcome....2199
Follow-on Procedure....2199
General Test Procedures....2200
Coolant Heater Assembly Test....2200
Overview....2200
Tools Required....2200
Equipment Condition....2200
Test Setup....2200
Test Procedure....2200
Expected Outcome....2201
Follow-On Procedure....2201
Oil Pan Heater Test....2202
Overview....2202
Tools Required....2202
Equipment Condition....2202
Test Setup....2202
Test Procedure....2202
Expected Outcome....2203
Follow-On Procedure....2203
Relay Diagnostics....2204
Overview....2204
Relay Diagnostics Applicability Table....2204
Relay Test 1 - Switched-86 GND....2205
Overview....2205
Tools Required....2205
Equipment Conditions....2205
Test Setup....2205
Test Procedure....2205
Expected Outcome....2206
Follow-on Procedure....2206
Relay Test 2 ? Switched-86 PWR....2207
Overview....2207
Tools Required....2207
Equipment Conditions....2207
Test Setup....2207
Test Procedure....2207
Expected Outcome....2208
Follow-on Procedure....2208
Relay Test 3 ? Switched-85 GND....2209
Overview....2209
Tools Required....2209
Equipment Conditions....2209
Test setup....2209
Test Procedure....2209
Expected Outcome....2211
Follow-on Procedure....2211
Relay Test 4 ? Switched-85 Shared 30....2212
Overview....2212
Tools Required....2212
Equipment Conditions....2212
Test setup....2212
Test Procedure....2212
Expected Outcome....2214
Follow-on Procedure....2214
Relay Test 5 ? Switched-85 GND, FMI 4....2215
Overview....2215
Tools Required....2215
Equipment Conditions....2215
Test setup....2215
Test Procedure....2215
Expected Outcome....2216
Follow-on Procedure....2216
Relay Test 6 ? Switched-86 PWR, No Code....2217
Overview....2217
Tools Required....2217
Equipment Conditions....2217
Test setup....2217
Test Procedure....2217
Expected Outcome....2218
Follow-on Procedure....2218
Relay Test 7 ? Switched-85 GND, No Code....2219
Overview....2219
Tools Required....2219
Equipment Conditions....2219
Test setup....2219
Test Procedure....2219
Expected Outcome....2220
Follow-on Procedure....2220
Coolant Test Procedures....2221
Deaeration Tank Cap Test....2221
Overview....2221
Tools Required....2221
Equipment Condition....2222
Test Setup....2223
Test Procedure....2223
Expected Outcome....2223
Follow-on Procedure....2223
Cooling System Pressure Test....2224
Overview....2224
Tools Required....2224
Equipment Condition....2224
Test Setup....2225
Test Procedure....2226
Expected Outcome....2226
Follow-on Procedure....2227
Coolant Over-Flow / Over-Temperature Test....2228
Overview....2228
Tools Required....2228
Equipment Condition....2228
Test Setup....2228
Test Procedure....2228
Expected Outcome....2228
Follow-On Procedure....2228
Thermostat Operational Test....2229
Overview....2229
Tools Required....2229
Equipment Condition....2229
Test Setup....2229
Test Procedure....2229
Expected Outcome....2229
Follow-On Procedure....2229
Engine Cooling Fan Test....2230
Overview....2230
Tools Required....2230
Equipment Condition....2230
Test Setup....2230
Test Procedure....2230
Expected outcome....2231
Air Compressor Coolant Leak Test....2232
Overview....2232
Tools Required....2232
Equipment Condition....2232
Test Setup....2232
Test Procedure....2233
Expected Outcome....2233
Follow-on Procedure....2233
Air Compressor Overflow Test....2234
Overview....2234
Tools Required....2234
Equipment Condition....2234
Test Setup....2234
Test Procedure....2234
Expected Outcome....2234
Follow-on Procedure....2234
Combustion in Cooling System Test....2235
Overview....2235
Tools Required....2235
Equipment Condition....2235
Test set-up....2235
Test Procedure....2236
Expected Outcome....2236
Follow-On Procedure....2236
On-Engine EGR Cooler Leak Test....2237
Overview....2237
Tools Required....2237
Equipment Condition....2237
Test Setup....2237
Test Procedure....2239
Expected Outcome....2239
Follow-On Procedure....2239
Instrument Cluster Temperature Gauge Validation Test....2240
Overview....2240
Tools Required....2240
Equipment Condition....2240
Test Setup....2240
Test Procedure....2240
Expected Outcome....2241
Follow-On Procedure....2241
Engine Oil Tests....2242
Oil Cooler Pressure Test....2242
Overview....2242
Tools Required....2242
Equipment Condition....2242
Test Setup....2242
Test Procedure....2243
Expected Outcome....2244
Follow-on Procedure....2244
Oil Pressure Verification Test....2245
Overview....2245
Tools Required....2245
Equipment Condition....2245
Test Setup....2245
Test Procedure....2246
Expected Outcome....2246
Follow-on Procedure....2247
Instrument Cluster Engine Oil Pressure Gauge Validation Test....2248
Overview....2248
Tools Required....2248
Equipment Condition....2248
Test Setup....2249
Test Procedure....2249
Expected Outcome....2250
Follow-On Procedure....2250
Oil Breather Separator Test....2251
Overview....2251
Tools Required....2251
Equipment Condition....2251
Test Setup....2251
Test Procedure....2252
Expected Outcome....2252
Follow-on Procedure....2252
Engine System Inspections....2253
Fuel System Inspection....2253
Overview....2253
Tools Required....2253
Equipment Condition....2253
Inspection Procedure....2253
Expected Outcome....2253
Fuel Quality Inspection....2254
Overview....2254
Tools Required....2254
Inspection Procedure....2255
Expected Outcome....2255
Fuel Level Inspection....2256
Overview....2256
Tools Required....2256
Equipment Condition....2256
Inspection Procedure....2256
Expected Outcome....2256
Engine Oil Level and Quality Check....2257
Overview....2257
Tools Required....2257
Equipment Condition....2257
Inspection Procedure....2257
Expected Outcome....2258
Coolant Level Inspection....2259
Overview....2259
Tools Required....2259
Equipment Condition....2259
Inspection Procedure....2259
Expected Outcome....2259
Coolant Quality Inspection....2260
Overview....2260
Tools Required....2260
Equipment Condition....2260
Inspection Procedure....2260
Expected Outcome....2260
Coolant in Exhaust Inspection....2261
Overview....2261
Tools Required....2261
Inspection Procedure....2261
Expected Outcome....2261
Interstage Cooler (ISC) Inspection....2262
Overview....2262
Tools Required....2262
Equipment Condition....2262
Inspection Procedure....2263
Expected Outcome....2263
Coolant Leak Visual Inspection ....2264
Overview....2264
Tools Required....2264
Equipment Condition....2264
Inspection Procedure....2264
Expected Outcome....2264
Coolant To Intake Inspection....2265
Overview....2265
Tools Required....2265
Equipment Condition....2265
Inspection Procedure....2266
Expected Outcome....2266
Charge Air Cooler Inspection....2267
Overview....2267
Tools Required....2267
Equipment Condition....2267
Inspection Procedure....2267
Expected Outcome....2268
Intake Air Inspection....2269
Overview....2269
Tools Required....2269
Equipment Condition....2269
Inspection Procedure....2269
Expected Outcome....2269
Front Gear Train Coolant Leak Inspection....2270
Overview....2270
Tools Required....2270
Equipment Condition....2270
Inspection Procedure....2270
Expected Outcome....2271
Exhaust and Aftertreatment System Inspection....2272
Overview....2272
Tools Required....2272
Equipment Condition....2272
Inspection Procedure....2272
Expected Outcome....2273
Diesel Particulate Filter (DPF) Inspection....2274
Overview....2274
Tools Required....2274
Equipment Condition....2274
Inspection Procedure....2275
Expected Outcome....2276
Diesel Oxidation Catalyst (DOC) Inspection....2277
Overview....2277
Tools Required....2277
Equipment Condition....2277
Inspection Procedure....2278
Expected Outcome....2278
Selective Catalyst Reduction (SCR) Inspection....2279
Overview....2279
Tools Required....2279
Equipment Condition....2279
Inspection Procedure....2279
Expected Outcome....2280
Follow-On Procedure....2280
Diesel Exhaust Fluid Dosing Unit (DEFD) Inspection....2281
Overview....2281
Tools Required....2281
Equipment Condition....2281
Inspection Procedure....2282
Expected Outcome....2283
Decomposition Reactor Tube Inspection....2284
Overview....2284
Tools Required....2284
Equipment Condition....2284
Inspection Procedure....2284
Expected Outcome....2285
Diesel Exhaust Fluid (DEF) Quality Inspection....2286
Overview....2286
Tools Required....2286
Equipment Condition....2286
Inspection Procedure....2286
Expected Outcome....2286
Diesel Exhaust Fluid (DEF) Level & Gauge Inspection....2287
Overview....2287
Tools Required....2287
Equipment Condition....2287
Inspection Procedure....2287
Expected Outcome....2288
Coolant to Engine Oil Inspection ....2289
Overview....2289
Tools Required....2289
Inspection Procedure....2289
Expected Outcome....2289
Oil Pressure Regulator Inspection....2290
Overview....2290
Tools Required....2290
Equipment Condition....2290
Inspection Procedure....2291
Expected Outcome....2291
Cylinder Sleeve Cavitation and Crack Inspection....2292
Overview....2292
Tools Required....2292
Equipment Condition....2292
Inspection Procedure....2292
Expected Outcome....2292
Oil and Crankcase Inspection....2293
Overview....2293
Tools Required....2293
Equipment Condition....2293
Inspection Procedure....2293
Expected Outcome....2295
High-Pressure (HP) Turbocharger Radial Play Inspection....2296
Overview....2296
Tools Required....2296
Equipment Condition....2296
Inspection Procedure....2296
Expected Outcome....2296
Batteries and Electrical System Inspection....2297
Overview....2297
Tools Required....2297
Equipment Condition....2297
Inspection Procedure....2297
Expected Outcome....2297
Aftertreatment....2298
Snap Acceleration Test....2298
Overview....2298
Tools Required....2298
Equipment Condition....2298
Test Setup....2298
Test Procedure....2298
Expected Outcome....2298
Follow-On Procedure....2298
Downstream Injection System Operation Test....2299
Overview....2299
Tools Required....2299
Equipment Condition....2299
Test Setup....2299
Test Procedure....2300
Expected Outcome....2301
Follow-on Procedure....2301
Table of Contents....2302
All Ratings....2304
Engine Specifications....2304
Key-On Engine-Off....2305
Position Sensors....2305
Engine Cranking Specs....2306
Low Idle, No Load, Stabilized Engine Operating Temperature Specs....2307
High Idle, No Load, Stabilized Engine Operating Temperature Specs....2308
Full Load, Rated Speed on Dynamometer, Stabilized Engine Operating Temperature Specs....2309
Engine Coolant Temperatures ECT1, ECT2, Engine Oil Temp, Intake Manifold Temp (IMAT) Specs....2310
Intake Air Temp (IAT) Specs....2311
Diesel Oxidation Catalyst Intake Temp (DOCIT), Diesel Particulate Filter Intake Temp (DPFIT), Diesel Particulate Outlet Temp (DPFOT) Specs....2312
Soot Load Level versus Exhaust Gas Target Temperature Chart....2313
Overview....2313
Soot Load Level versus Exhaust Gas Target Temperature Chart....2313
Other Components Specs....2314
Navistar? 9 (9.3L)....2315
300 hp @ 2000 rpm (12NWC)....2315
315 hp @ 2000 rpm (12NWD)....2316
330 hp @ 2000 rpm (12NWE)....2317
Navistar? 10 (9.3L)....2318
310 hp @ 2000 rpm (12NWG)....2318
330 hp @ 2000 rpm (12NWH)....2319
350 hp @ 2000 rpm (12NWJ)....2320
Fluids....2321
Fluid Specifications and Info....2321
Fuel....2321
Ultra Low Sulfur Diesel (ULSD)....2321
Acceptable Fuel Blends....2321
Use of Higher Biodiesel Fuel Blends (B6 to B20)....2321
Engine Lubrication Oil....2321
SAE Oil Viscosity Grades and Temperature Ranges....2322
Coolant....2323
Cooling System Capacity....2323
Coolant Mixtures....2323
Table of Contents....2324
Electrical Tools....2326
180-Pin Breakout Box....2326
Breakout Harness 18-050-01 (20-way DEF Harness Interconnect)....2327
Breakout Harness 18-650-01 (Ammonia (NH3) Sensor)....2327
Breakout Harness 18-801-01 (Ammonia (NH3) Sensor Module)....2328
Breakout Harness 18-909-01 (DEF Supply Module)....2328
Breakout Harness 18-047-01 DEF Line 3 Heater (Pressure)....2329
Breakout Harness 18-046-01 DEF Line 2 Heater (Return)....2329
Breakout Harness 18-045-01 DEF Line 1 Heater (Supply)....2330
Breakout Harness 18-124-01 (DEF Tank Level and Temperature Sensor)....2330
Breakout Harness 18-649-01 (NOx Out and DOC / DPF Temperature Sensor Module)....2331
Breakout Harness 12-575-01 (DPF Differential Pressure / Outlet Pressure Sensor)....2331
Breakout Harness 18-648-01 (NOx In Sensor Module and SCR Temperature Sensor Module)....2332
Breakout Harness 12-574-01 (8-way DPF Jumper Harness)....2332
Breakout Harness 18-250-01 (12-way SCR Jumper Harness)....2333
Breakout Harness 18-500-01 (12-way AFT Interconnect)....2333
Digital Multimeter (DMM) ZTSE4357....2334
Breakout Harness ZTSE6023 (EFP)....2334
International? Electronic Engine Terminal Test Kit ZTSE4435C....2335
Breakout Harness ZTSE4485A (APP)....2336
Breakout Harness ZTSE4760A (DOCIT, DPFIT, and DPFOT)....2336
Breakout Harness ZTSE4735A (ETV)....2337
Amp Clamp ZTSE4575....2337
3-Banana Plug Harness ZTSE4498....2338
500-Ohm Resistor Harness ZTSE4497....2338
Breakout Harness ZTSE4484 (IPR)....2339
Breakout Harness ZTSE4602 (EOT, ECT1, and AFTFSV)....2339
Breakout Harness ZTSE4674 (ECM and ACT PWR Relays)....2340
Breakout Harness ZTSE4830 (AFTFIS)....2340
Breakout Harness ZTSE4831 (TC2WG)....2341
Breakout Harness ZTSE4834 (EBPV)....2341
Breakout Harness ZTSE4850 (IMP, ICP, EOP, FDP, and EBP)....2342
Breakout Harness ZTSE4908 (EFAN)....2342
Breakout Harness ZTSE4946 (EGT)....2343
Breakout Harness ZTSE4948 (EGR)....2343
Breakout Harness ZTSE4950 (CKP)....2344
Breakout Harness ZTSE4951 (CMP)....2344
Breakout Harness ZTSE4952 (ICP, ECB, and ECBP)....2345
Breakout Harness ZTSE4993 (IMT)....2345
Breakout Harness ZTSE6002 (WIF)....2346
Breakout Harness ZTSE6020 (24-pin)....2346
Breakout Harness ZTSE6021 (AFTFD)....2346
Breakout Harness ZTSE6025 (IAH)....2347
Breakout Harness ZTSE6027 (AFTFP)....2347
Under Valve Cover (UVC) ZTSE4793....2347
DEF Tank Heat Coolant Flow Valve ZTSE4827....2348
Diesel Exhaust Fluid Dosing Unit (DEFDU) ZTSE4828....2348
Mass Air Flow (MAF) Sensor ZTSE4960....2349
Noid Lamp 15-909-01....2349
Mechanical Tools....2350
Radiator Pressure Test Kit ZTSE2384....2350
Pressure Test Kit ZTSE4409....2350
Interstage Cooler Test Kit ZTSE4937....2351
Oil Cooler Test Plate ZTSE4939....2352
Cylinder Head Pressure Test Adapter ZTSE4289A....2353
Thermostat Opening Pressure Test Adapter ZTSE4647....2353
Water Supply Press Test Adapter ZTSE4648....2354
ICP Adapter Pressure Test Fitting ZTSE4927....2354
High Pressure Test Gauge ZTSE4954....2355
Pressure Gauge Adapter 18-538-01....2356
IPR Plug Tester ZTSE4816....2356
Crankcase Pressure Test Tool ZTSE4039....2357
Slack Tube? Manometer ZTSE2217A....2358
Fuel Pressure Gauge ZTSE4681....2359
Fuel Pressure Test Kit ZTSE4657....2360
Charge Air Cooler Test Kit ZTSE4341....2360
EGR Mixing Bowl Guide Pins ZTSE4945....2361
EGR Valve Puller ZTSE4941....2361
Fuel Intake Restriction and Aeration Tool ZTSE6009....2362
Fuel/Oil Pressure Test Coupler ZTSE4526....2362
Fuel Test Fitting ZTSE4692....2363
ICP Test Kit ZTSE4655....2363
Turbo Lifting Bracket ZTSE4942....2364
UV Leak Detection Kit ZTSE4618....2364
Clean Fuel Source Tool 15-637-01....2365
Table of Contents....2366
Engine Component Locator....2368
Aftertreatment Component Locator....2376
Table of Contents....2378
Engine Identification....2382
Engine Serial Number....2382
Engine Serial Number Examples:....2382
Engine Serial Number Codes:....2382
Engine Emission Label....2383
Engine Accessory Labels....2383
Air Management System....2385
Air Flow-Pre Combustion....2386
Air Flow-Post Combustion....2386
Air Management Components....2386
Turbochargers....2386
Interstage Cooler (ISC)....2387
Exhaust Gas Recirculation (EGR) System....2388
The EGR system includes the following: ....2388
Exhaust Gas Recirculation (EGR) Valve....2389
Exhaust Gas Recirculation (EGR) Closed Loop System....2389
Crankcase Ventilation System....2390
Aftertreatment System....2392
Aftertreatment (AFT) System....2392
AFT Control System....2392
DPF....2393
DOC....2393
Selective Catalyst Reduction (SCR) Catalyst ....2393
Decomposition reactor tube ....2393
Sensors....2393
Exhaust Back Pressure Valve (EBPV)....2393
AFT Conditions and Responses ....2393
Diesel Exhaust Fluid (DEF) Injection ....2394
Downstream Injection System ....2395
Fuel Management System....2396
Fuel Management System....2396
Injection Control Pressure (ICP) System....2397
High-Pressure Oil System....2398
Injection Control Pressure (ICP) Closed Loop System ....2398
ICP Control System ....2399
Fuel Injector....2400
Intensifier Piston and Plunger....2401
Plunger and Barrel....2401
Injector Needle....2401
Fuel Injector Operation....2401
Fill Stage ....2402
Injection....2402
End of Injection ....2403
Fuel Supply System....2404
Fuel Supply System Flow ....2405
Intake Air Heater System....2409
Intake Air Heater System....2409
Intake Air Heater (IAH)....2409
Engine Lubrication System....2410
Engine Cooling System....2412
Cooling System Description....2412
Cooling System Components....2413
Coolant Heater (optional)....2413
Thermostat Operation....2413
Electronic Control System ....2416
Electronic Control System Components ....2416
Operation and Function....2416
Doser Control Unit (DCU)....2416
Reference Voltage (VREF)....2416
Microprocessor....2416
Diagnostic Trouble Codes....2416
Microprocessor Memory....2416
Read Only Memory (ROM)....2417
Random Access Memory (RAM)....2417
Actuator Control....2417
ECM Actuators and Sensors....2418
Exhaust Gas Recirculation Valve (EGRV)....2419
Intake Air Heater (IAH) System....2419
Electric Fuel Pump (EFP)....2419
Engine Throttle Valve (ETV) and Engine Throttle Valve Position (ETP) Sensor....2419
Turbocharger 2 Wastegate (TC2WG) position valve....2419
Exhaust Back Pressure Control (EBPC)....2420
Engine Compression Brake Output 1 (ECB1) valve....2420
Injectors....2420
Injection Pressure Regulator (IPR) valve....2420
ACM Actuators....2421
AFT Fuel Shutoff (AFTFSO)....2422
Aftertreatment Fuel Pressure Control (AFTFPC)....2422
Diesel Exhaust Fluid Dosing Unit (DEFD)....2422
Diesel Exhaust Fluid Unit Heater Relay (DEFSMH Relay)....2422
Diesel Exhaust Fluid Line Heater Relay (DEFLHR)....2422
EF Supply Line Heater (DEFSLH)....2422
DEF Return Line Heater (DEFRLH)....2422
DEF Pressure Line Heater (DEFPLH)....2423
DEF Tank Heater Valve (DEFTHV)....2423
Diesel Exhaust Fluid Supply Module Heater (DEFSMH)....2423
Diesel Exhaust Fluid Supply Pump (DEFSP) and DEF Tank Temperature (DEFTT) Sensors....2423
Diesel Exhaust Fluid Reverting Control Valve (DEFRCV)....2423
Engine and Vehicle Sensors....2423
Engine Temperature Sensors....2423
Engine Coolant Temperature 1 (ECT1) Sensor....2424
Engine Oil Temperature (EOT) Sensor....2424
Turbocharger 2 Compressor Intake Temperature (TC2CIT) Sensor....2424
Exhaust Gas Temperature (EGT) Sensor....2424
Charge Air Cooler Outlet Temperature (CACOT) Sensor....2425
Intake Air Heater (IAT) Sensor....2425
Intake Manifold Temperature (IMT) Sensor....2425
Ambient Air Temperature (AAT) Sensor....2425
Aftertreatment Temperature Sensors....2425
Diesel Exhaust Fluid Tank Level and Temperature (DEFTLT) Sensor Module....2426
Diesel Oxidation Catalyst (DOC) / Diesel Particulate Filter (DPF) Temperature Sensor Module....2426
Diesel Oxidation Catalyst Intake Temperature (DOCIT) Sensor....2426
Diesel Particulate Filter Intake Temperature (DPFIT) Sensor....2426
Diesel Particulate Filter Outlet Temperature (DPFOT) Sensor....2426
Selective Catalyst Reduction (SCR) Temperature Sensor Module....2426
Variable Capacitance Sensors....2427
Fuel Delivery Pressure (FDP) sensor....2427
Engine Oil Pressure (EOP) Sensor....2428
Exhaust Back Pressure (EBP) Sensor....2428
Mass Air Flow (MAF) Sensor....2428
Intake Manifold Pressure (IMP) Sensor....2428
Aftertreatment Fuel Pressure 1 (AFTFP1) sensor....2428
Aftertreatment Fuel Temperature (AFTFT) sensor....2428
Aftertreatment Fuel Pressure 2 (AFTFP2) sensor....2428
DEF Line Pressure (DEFLP) sensor....2429
Diesel Particulate Filter Differential Pressure (DPFDP) / DPF Outlet Pressure (DPFOP) sensor....2429
Turbocharger 1 Turbine Outlet Pressure (TC1TOP)....2429
High-pressure Sensors....2429
Brake Control Pressure (BCP) Sensor....2429
Injection Control Pressure (ICP) Sensor....2430
Magnetic Pickup Sensors....2430
Crankshaft Position (CKP) Sensor....2430
Camshaft Position (CMP) Sensor....2430
Vehicle Speed Sensor (VSS)....2431
Crankcase Oil Separator Speed (CCOSS) Sensor....2431
Switches....2431
Driveline Disengagement Switch (DDS)....2431
Engine Coolant Level (ECL) Sensor....2431
Water In Fuel (WIF)....2432
Potentiometer Sensors....2432
Accelerator Pedal Position (APP)....2432
Engine Throttle Valve Control System....2433
Exhaust and Engine Brake System....2434
Exhaust Brake....2434
Engine Brake....2435
Exhaust Back Pressure Control (ECBC)....2435
Engine Compression Brake Output 1 (ECB1)....2436
Brake Pressure Relief Valve....2436
Exhaust Back Pressure (EBP) Sensor....2436
High-pressure Oil Manifold....2436
Operation....2436
Operation Modes....2438
Coast Mode....2438
Latched Mode....2438
Cruise Mode....2438
Chassis Mounted Features....2438
Charge Air Cooler (CAC)....2438
Additional Sensors....2438
Ammonia (NH3) Sensor Module....2438
Nitrogen Oxides (NOx) IN Sensor Module....2439
Nitrogen Oxides (NOx) OUT Sensor Module....2439
Oxygen Sensor (O2S)....2439
Humidity Sensor (HS)....2440
Relays....2441
ECM Power Relay....2442
Actuator Power Relay....2443
Engine Fan Relay....2444
Fuel Pump Relay....2444
Fuel Heater Relay....2445
Starter Relay....2446
Heavy Duty On Board Diagnostics (HD-OBD) Description....2447
Overview....2447
Table of Contents....2448
Standard Electronic Control Features....2450
Aftertreatment (AFT) System....2450
Intake Air Heater....2450
Coolant Temperature Compensation (CTC)....2450
Electronic Speedometer and Tachometer....2450
Engine Crank Inhibit (ECI)....2450
Electronic Governor Control....2450
Event Logging System....2450
Fast Idle Advance....2451
J1939 Datalink....2451
Service Diagnostics....2451
Optional Electronic Control Features....2452
Cruise Control....2452
Engine Brake....2452
Engine Warning Protection System (EWPS)....2452
Idle Shutdown Timer (IST)....2452
IST for California ESS Compliant Engines....2452
Engine Idle Shutdown Timer (IST for Federal ? Optional) ....2453
Automatic Engine Speed Control (AESC)....2453
Service Interval....2453
Traction Control....2453
Road Speed Limiter....2453
Table of Contents....2456
Abbreviations and Acronyms....2458
Abbreviations and Acronyms....2458
Table of Contents....2468
Terminology....2470
Terms....2470
tables....40
Technical Service Literature....40
SPN....785
FMI....785
Description....785
Voltage Check at Relay....1030
Voltage Check at ECM....1030
Harness Resistance Check ? ECM to Relay....1031
Operational Voltage Check....1031
Harness Resistance Check ? Relay to Battery....1031
SPN....1871
FMI....1871
Description....1871
SPN....1889
FMI....1889
Description....1889
Air Management Test Setup....2071
Navistar? 9, and 10 Diesel Engines....2304
Key-On Engine-Off....2305
Key-On Engine-Off....2305
Engine Cranking....2306
Low Idle, no load, stabilized engine operating temperature....2307
Low Idle, no load, stabilized engine operating temperature....2307
High Idle, Parasitic load, at stabilized operating temperature....2308
Crankcase Pressure....2308
Full Load, Rated Speed on Dynamometer, Stabilized Engine Operating Temperature....2309
Engine Component Locations....2373
Component....2373
Location....2373
SCR Switchback Assembly Component Locator Table....2377
Component....2377
Location....2377
0000003721 (12?2014) - N9 and N10 Engine Diagnostic Manual....2483
toc....2485
Table of Contents....2485
Safety Terminology....2489
Safety Instructions....2489
Work Area....2489
Safety Equipment....2489
Protective Measures....2489
Vehicle....2489
Engine....2490
Fire Prevention....2490
Batteries....2490
Compressed Air....2490
Tools....2490
Fluids Under Pressure....2491
Fuel....2491
Removal of Tools, Parts, and Equipment....2491
Table of Contents....2493
Diagnostic Trouble Code (DTC?s) List....2497
Operational Checkout Procedures....2509
1.0 - Preliminary Vehicle Operational Checkout Procedure....2509
2.0 - Engine Does Not Start Operational Checkout Procedure....2512
Overview....2512
3.0 - Engine Hard to Start Operational Checkout Procedure....2516
Overview....2516
4.0 - Engine Running, Engine Not Under Load Operational Checkout Procedure....2520
Overview....2520
5.0 - Engine Running, Engine Under Load Operational Checkout Procedure....2522
Overview....2522
6.0 - Cooling System Operational Checkout Procedure....2524
7.0 - Lube Oil System Operational Checkout Procedure....2525
8.0 - Fuel System Operational Checkout Procedure....2526
9.0 - Engine Compression Brake Operational Checkout Procedure....2527
10.0 - SCR Aftertreatment Operational Checkout Procedure....2528
Overview....2528
Test Procedure....2528
11.0 - ECM Loss of Communication....2529
Overview....2529
Possible Causes....2529
Test Procedure....2529
Engine Does Not Start Symptoms....2535
2.1 - Engine Cranks Fast, Slow, or Does Not Crank....2535
Overview....2535
Possible Causes....2535
Test Procedure....2535
2.2 - Engine No Start, Cold Ambient Temperature....2539
Overview....2539
Possible Causes....2539
Test Procedure....2539
2.3 - Engine at Operating Temperature, No Re-Start....2540
Overview....2540
Possible Causes....2540
Test Procedure....2541
2.4 - Engine Never Starts....2543
Overview....2543
Possible Causes....2543
Test Procedure....2543
Engine Hard to Start Symptoms....2546
3.1 - Engine Hard to Start, Cold Ambient Temperature....2546
Overview....2546
Possible Causes....2546
Test Procedure....2546
3.2 - Engine at Operating Temperature, Hard to Re-Start....2548
Overview....2548
Possible Causes....2548
Test Procedure....2548
3.3 - Engine Starts, Then Stalls....2550
Overview....2550
Possible Causes....2550
Test Procedure....2550
Engine Running, Engine Not Under Load Symptoms....2552
4.1 - Rough Idle....2552
Overview....2552
Possible Causes....2552
Test Procedure....2552
4.2 - Engine Unable To Reach Rated Speed (No Load)....2556
Overview....2556
Possible Causes....2556
Test Procedure....2556
4.3 - Popping Noise from Intake....2558
Overview....2558
Possible Causes....2558
Test Procedure....2558
Engine Running, Engine Under Load Symptoms....2560
5.1 - Low Power (Slow Acceleration)....2560
Overview....2560
Possible Causes....2560
Test Procedure....2560
5.2 - Misfire (Stumble / Surge / Runs Rough)....2566
Overview....2566
Possible Causes....2566
Test Procedure....2567
5.3 - Engine Unable to Reach Desired Speed During PTO Operation....2570
Overview....2570
Possible Causes....2570
Test Procedure....2570
Engine Coolant Symptoms....2574
6.1 - Coolant Contaminated....2574
Overview....2574
Possible Causes....2574
Test Procedure....2574
6.2 - Coolant Loss....2575
Overview....2575
Possible Causes....2575
Test Procedure....2575
6.3 - Coolant Over-Temp....2577
Overview....2577
Possible Causes....2577
Test Procedure....2578
6.4 - Coolant Overflow....2580
Overview....2580
Possible Causes....2580
Test Procedure....2580
6.5 - Coolant Leak to Exhaust....2583
Overview....2583
Possible Causes....2583
Test Procedure....2584
6.6 - Coolant Leak to Intake....2587
Overview....2587
Possible Causes....2587
Test Procedure....2587
6.7 - Coolant Leak to Lube Oil ....2588
Overview....2588
Possible Causes....2588
Test Procedure....2588
Engine Lubrication Symptoms....2593
7.1 - Lube Oil Contamination....2593
Overview....2593
Possible Causes....2593
Test Procedure....2593
7.2 - Lube Oil to Coolant....2594
7.3 - Engine Oil to Intake....2595
Overview....2595
Possible Causes....2595
Test Procedure....2595
7.4 - Engine Oil to Exhaust....2597
Overview....2597
Possible Causes....2597
Test Procedure....2597
7.5 - Power Steering Fluid Leak to Lube Oil ....2598
7.6 - Low Oil Pressure....2599
Overview....2599
Possible Causes....2599
Test Procedure....2599
7.7 - High Oil Pressure....2602
Overview....2602
Possible Causes....2602
Test Procedure....2603
7.8 - Excessive Oil Consumption....2605
Fuel System Symptoms....2606
8.1 - Fuel Delivery Pressure....2606
Overview....2606
Possible Causes....2606
Test Procedure....2606
8.2 - Fuel in Engine Oil....2610
Engine Brake Symptoms....2612
9.1 - Engine Compression Brake Inoperative....2612
Possible Causes....2612
Test Procedure....2612
9.2 - Engine Compression Brake Engaged When Not Commanded....2615
Possible Causes....2615
Test Procedure....2615
Aftertreatment Symptoms....2617
10.1 - Parked Regeneration Will Not Activate....2617
Overview....2617
Possible Causes....2617
Test Procedure....2617
10.2 - Black Smoke ....2619
Overview....2619
Possible Causes....2619
Test Procedure....2619
10.3 - White Smoke....2624
Overview....2624
Possible Causes....2624
Test Procedure....2624
Fault Code Diagnostics....2628
Section Information....2628
AAT Sensor (Ambient Air Temperature)....2629
Overview of AAT Sensor....2629
Overview ....2629
SPN 171 FMI 2 - AAT Signal Erratic, Intermittent, or Incorrect....2630
Fault Overview....2630
Lamp Reaction....2630
Associated Faults....2630
Fault Facts....2630
Drive Cycle to Determine Fault Status....2630
Possible Causes....2630
SPN 171 FMI 3 - AAT Signal Out of Range HIGH....2632
Fault Overview....2632
Lamp Reaction....2632
Associated Faults....2632
Fault Facts....2632
Drive Cycle....2632
Possible Causes....2632
Pin-Point Test (SPN 171 FMI 3)....2634
Tools Required....2634
SPN 171 FMI 4 - AAT Signal Out of Range LOW....2638
Fault Overview....2638
Lamp Reaction....2638
Associated Faults....2638
Fault Facts....2638
Drive Cycle to Determine Fault Status....2638
Possible Causes....2638
Pin-Point Tests (SPN 171 FMI 4)....2640
Tools Required....2640
AFT (Aftertreatment) System....2642
Overview of AFT System Group....2642
Overview....2643
SPN 3251 FMI 0 - DPFDP excessively HIGH (Plugged filter)....2644
Fault Overview....2644
Lamp Reaction....2644
Associated Faults....2644
Fault Facts....2644
Drive Cycle to Determine Fault Status....2644
Possible Causes....2644
SPN 3251 FMI 15 - DPF Soot Load - Least Severe Level....2646
Fault Overview....2646
Lamp Reaction....2646
Associated Faults....2646
Fault Facts....2646
Drive Cycle to Determine Fault Status....2646
Possible Causes....2646
SPN 3251 FMI 16 - DPF Soot Load - Moderately Severe Level....2648
Fault Overview....2648
Lamp Reaction....2648
Associated Faults....2648
Fault Facts....2648
Drive Cycle to Determine Fault Status....2648
Possible Causes....2648
SPN 3695 FMI 2- DPF Regen Inhibit Switch erratic, intermittent, or incorrect....2650
Fault Overview....2650
Lamp Reaction....2650
Associated Faults....2650
Fault Facts....2650
Drive Cycle to Determine Fault Status....2650
Possible Causes....2650
SPN 3695 FMI 19 - DPF Regen Inhibit Switch status not detected on J1939 ....2652
Fault Overview....2652
Lamp Reaction....2652
Associated Faults....2652
Fault Facts....2652
Drive Cycle to Determine Fault Status....2652
Possible Causes....2652
SPN 3703 FMI 31 - DPF Active Regeneration Inhibited Due to Inhibit Switch....2654
Fault Overview....2654
Lamp Reaction....2654
Associated Faults....2654
Fault Facts....2654
Drive Cycle to Determine Fault Status....2654
Possible Causes....2654
SPN 3713 FMI 31 - DPF Active Regeneration Inhibited Due to System Timeout....2656
Fault Overview....2656
Lamp Reaction....2656
Associated Faults....2656
Drive Cycle to Determine Fault Status....2656
Fault Fact....2656
Possible Causes....2656
SPN 3719 FMI 0: DPF Soot Load - Highest (level 3/3)....2658
Fault Overview....2658
Lamp Reaction....2658
Associated Faults....2658
Fault Facts....2658
Drive Cycle to Determine Fault Status....2658
Possible Causes....2658
SPN 3719 FMI 15 DPF Soot Load - Lowest (level 1/3)....2660
Fault Overview....2660
Lamp Reaction....2660
Associated Faults....2660
Fault Facts....2660
Drive Cycle to Determine Fault Status....2660
Possible Causes....2660
SPN 3719 FMI 16 - DPF Soot Load - Moderate (level 2/3)....2662
Fault Overview....2662
Lamp Reaction....2662
Associated Faults....2662
Fault Facts....2662
Drive Cycle to Determine Fault Status....2662
Possible Causes....2662
SPN 3750 FMI 31 - DPF Regen inhibited due to low exhaust temperatures....2664
Fault Overview....2664
Lamp Reaction....2664
Associated Faults....2664
Fault Facts....2664
Drive Cycle to Determine Fault Status....2664
Possible Causes....2664
SPN 3936 FMI 14 - DOC / DPF Temperature module (Incorrect Part)....2666
Fault Overview....2666
Lamp Reaction....2666
Associated Faults....2666
Fault Facts....2666
Drive Cycle to Determine Fault Status....2666
Possible Causes....2666
SPN 3936 FMI 15 - DPF System above Warning Pressure....2668
Fault Overview....2668
Lamp Reaction....2668
Associated Faults....2668
Fault Facts....2668
Drive Cycle to Determine Fault Status....2668
Possible Causes....2668
SPN 3936 FMI 16 - DPF System above Maximum Pressure....2672
Fault Overview....2672
Lamp Reaction....2672
Associated Faults....2672
Fault Facts....2672
Drive Cycle to Determine Fault Status....2672
Possible Causes....2672
SPN 4795 FMI 31 - DPFDP Excessively LOW (Sensor/Circuit Fault or Missing DPF)....2676
Fault Overview....2676
Lamp Reaction....2676
Associated Faults....2676
Fault Facts....2676
Drive Cycle to Determine Fault Status....2676
Possible Causes....2676
SPN 4796 FMI 31 - Diesel Oxidation Catalyst Missing....2678
Fault Overview....2678
Lamp Reaction....2678
Associated Faults....2678
Fault Facts....2678
Drive Cycle to Determine Fault Status....2679
Possible Causes....2679
SPN 5298 FMI 17 - DOC Efficiency fault, Temperature below minimum Regen Aborted....2681
Fault Overview....2681
Lamp Reaction....2681
Associated Faults....2681
Fault Facts....2681
Drive Cycle to Determine Fault Status....2681
Possible Causes....2681
SPN 5298 FMI 18 - DOC Efficiency fault, Temperature below minimum....2684
Fault Overview....2684
Lamp Reaction....2684
Associated Faults....2684
Fault Facts....2684
Drive Cycle to Determine Fault Status....2684
Possible Causes....2684
SPN 5319 FMI 31 - DPF incomplete Regeneration....2686
Fault Overview....2686
Lamp Reaction....2686
Associated Faults....2687
Fault Facts....2687
Drive Cycle to Determine Fault Status....2687
Possible Causes....2687
AFT: FEC (Aftertreatment Fuel Enable Control)....2691
Overview of AFT: FEC Sensor Group....2691
Overview....2691
SPN 3482 FMI 3 - AFT Fuel Enable Control Valve short to PWR....2692
Fault Overview....2692
Lamp Reaction....2692
Associated Faults....2692
Fault Facts....2692
Drive Cycle to Determine Fault Status....2692
Possible Causes....2692
Pin-Point Tests (SPN 3482 FMI 3)....2694
Tools Required....2694
SPN 3482 FMI 4 - AFT Fuel Enable Control Valve open or short to GND....2702
Fault Overview....2702
Lamp Reaction....2702
Associated Faults....2702
Fault Facts....2702
Drive Cycle to Determine Fault Status....2702
Possible Causes....2702
Pin-Point Tests (SPN 3482 FMI 4)....2704
Tools Required....2704
AFT: FP1 / AFT: FT (Aftertreatment Fuel Pressure 1 / Aftertreatment Fuel Temperature) Sensor....2712
Overview of AFT: FP1 / AFT: FT Sensor Group....2712
Overview....2712
SPN 3480 FMI 3 - AFT: FP1 signal Out of Range HIGH....2714
Fault Overview....2714
Lamp Reaction....2714
Associated Faults....2714
Fault Facts....2714
Drive Cycle to Determine Fault Status....2714
Possible Causes....2714
Pin-Point Tests (SPN 3480 FMI 3)....2716
Tools Required....2716
SPN 3480 FMI 4 - AFTFP1 signal Out of Range LOW....2721
Fault Overview....2721
Lamp Reaction....2721
Associated Faults....2721
Fault Facts....2721
Drive Cycle to Determine Fault Status....2721
Possible Causes....2721
Pin-Point Tests (SPN 3480 FMI 4)....2723
AFT: FP1 Circuit....2723
Tools Required....2723
SPN 5456 FMI 2 - AFTFT Signal Erratic, Intermittent, or Incorrect....2728
Fault Overview....2728
Lamp Reaction....2728
Associated Faults....2728
Fault Facts....2728
Drive Cycle....2728
Possible Causes....2728
Pin - Point Tests (SPN 5456 FMI 2)....2730
Tools Required....2730
SPN 5456 FMI 3 - AFTFT Signal Out of Range - HIGH....2733
Fault Overview....2733
Lamp Reaction....2733
Associated Faults....2733
Fault Facts....2733
Drive Cycle to Determine Fault Status....2733
Possible Causes....2733
Pin-Point Tests (SPN 5456 FMI 3)....2735
Tools Required....2735
SPN 5456 FMI 4 - AFTFT Signal Out of Range LOW....2739
Fault Overview....2739
Lamp Reaction....2739
Associated Faults....2739
Fault Facts....2739
Drive Cycle to Determine Fault Status....2739
Possible Causes....2739
Pin-Point Tests (SPN 5456 FMI 4)....2741
Tools Required....2741
AFT: FP2 (Aftertreatment Fuel Pressure 2) Sensor....2743
Overview of AFT: FP2 Sensor Group....2743
Overview....2743
SPN 3556 FMI 0 - AFT Fuel Pressure 2 excessively high (Restricted injection)....2744
Fault Overview....2744
Lamp Reaction....2744
Associated Faults....2744
Fault Facts....2744
Drive Cycle to Determine Fault Status....2744
Possible Causes....2744
SPN 3556 FMI 1 - AFT Fuel Pressure 2 below desired (Possible system leak)....2746
Fault Overview....2746
Lamp Reaction....2746
Associated Faults....2746
Fault Facts....2746
Drive Cycle to Determine Fault Status....2746
Possible Causes....2746
Pin-Point Tests (SPN 3556 FMI 1)....2748
Tools Required....2748
SPN 3556 FMI 7 - AFT Fuel Injector not responding as expected....2752
Fault Overview....2752
Lamp Reaction....2752
Associated Faults....2752
Fault Facts....2752
Drive Cycle to Determine Fault Status....2752
Possible Causes....2752
SPN 4077 FMI 3 - AFTFP2 Signal Out of Range HIGH....2754
Fault Overview....2754
Lamp Reaction....2754
Associated Faults....2754
Fault Facts....2754
Drive Cycle to Determine Fault Status....2754
Possible Causes....2754
Pin-Point Tests (SPN 4077 FMI 3)....2756
Tools Required....2756
SPN 4077 FMI 4 - AFTFP2 Signal Out of Range LOW....2760
Fault Overview....2760
Lamp Reaction....2760
Associated Faults....2760
Fault Facts....2760
Drive Cycle to Determine Fault Status....2760
Possible Causes....2760
Pin-Point Tests (SPN 4077 FMI 4)....2762
Tools Required....2762
AFT: FPC (Aftertreatment Fuel Pressure Control) System....2765
Overview of AFT: FPC Sensor....2765
Overview....2765
SPN 3471 FMI 1 - AFT Fuel Pressure 1 below desired (Low system pressure)....2766
Fault Overview....2766
Lamp Reaction....2766
Associated Faults....2766
Fault Facts....2766
Drive Cycle to Determine Fault Status....2766
Possible Causes....2766
Pin-Point Tests (SPN 3471 FMI 1)....2768
Tools Required....2768
SPN 3471 FMI 7 - AFT Fuel Doser Valve not responding as expected....2772
Fault Overview....2772
Lamp Reaction....2772
Associated Faults....2772
Fault Facts....2772
Drive Cycle to Determine Fault Status....2772
Possible Causes....2772
Pin-Point Tests (SPN 3471 FMI 7)....2774
Tools Required....2774
SPN 3471 FMI 10 - AFT Fuel Pressure incorrect dosing pressure multiple events....2778
Fault Overview....2778
Lamp Reaction....2778
Associated Faults....2778
Fault Facts....2778
Drive Cycle to Determine Fault Status....2778
Possible Causes....2778
Pin-Point Tests (SPN 3471 FMI 10)....2780
Tools Required....2780
SPN 3479 FMI 3 - AFT Fuel Doser Valve Short to PWR....2784
Fault Overview....2784
Lamp Reaction....2784
Associated Faults....2784
Fault Facts....2784
Drive Cycle to Determine Fault Status....2784
Possible Causes....2784
Pin-Point Tests (SPN 3479 FMI 3)....2786
Tools Required....2786
SPN 3479 FMI 4 - AFT Fuel Doser Valve Short to GND....2792
Fault Overview....2792
Lamp Reaction....2792
Associated Faults....2792
Fault Facts....2792
Drive Cycle to Determine Fault Status....2792
Possible Causes....2792
Pin-Point Tests (SPN 3479 FMI 4)....2794
Tools Required....2794
SPN 3479 FMI 5 - AFT Fuel Pressure Valve Open or Short to GND low side....2804
Fault Overview....2804
Lamp Reaction....2804
Associated Faults....2804
Fault Facts....2804
Drive Cycle to Determine Fault Status....2804
Possible Causes....2804
Pin-Point Tests (SPN 3479 FMI 5)....2806
Tools Required....2806
SPN 3479 FMI 6 - AFT Fuel Doser Valve High Side Short circuit....2814
Fault Overview....2814
Lamp Reaction....2814
Associated Faults....2814
Fault Facts....2814
Drive Cycle to Determine Fault Status....2814
Possible Causes....2814
Pin-Point Tests (SPN 3479 FMI 6)....2816
Tools Required....2816
NH3 (Aftertreatment Ammonia) Sensor and Sensor Module....2824
Overview of NH3 Sensor Group....2824
Overview....2824
SPN 4377 FMI 2 - NH3 in range stuck fault....2827
Fault Overview....2827
Lamp Reaction....2827
Associated Faults....2827
Fault Facts....2827
Drive Cycle to Determine Fault Status....2828
Possible Causes....2828
SPN 4377 FMI 3 - NH3 Sensor signal Out of Range HIGH....2830
Fault Overview....2830
Lamp Reaction....2830
Associated Faults....2830
Fault Facts....2830
Drive Cycle to Determine Fault Status....2830
Possible Causes....2830
SPN 4377 FMI 4 - NH3 operation fault (circuit fault)....2832
Fault Overview....2833
Lamp Reaction....2833
Associated Faults....2833
Fault Facts....2833
Drive Cycle to Determine Fault Status....2833
Possible Causes....2833
SPN 4377 FMI 12 - NH3 internal chip error....2835
Fault Overview....2835
Lamp Reaction....2835
Associated Faults....2835
Fault Facts....2835
Drive Cycle to Determine Fault Status....2835
Possible Causes....2835
SPN 4377 FMI 13 - NH3 operation fault (wrong sensor installed)....2837
Fault Overview....2837
Lamp Reaction....2837
Associated Faults....2837
Fault Facts....2837
Drive Cycle to Determine Fault Status....2837
Possible Causes....2837
SPN 4377 FMI 19 - NH3 Sensor Module not detected on J1939....2839
Fault Overview....2839
Lamp Reaction....2839
Associated Faults....2839
Fault Facts....2839
Drive Cycle to Determine Fault Status....2839
Possible Causes....2839
Pin-Point Tests (SPN 4377 FMI 19)....2841
Tools Required....2841
SPN 4380 FMI 2 - NH3 signal erratic, intermittent, or incorrect....2851
Fault Overview....2851
Lamp Reaction....2851
Associated Faults....2851
Fault Facts....2851
Drive Cycle to Determine Fault Status....2851
Possible Causes....2851
Pin-Point Tests (SPN 4380 FMI 2)....2856
Tools Required....2856
SPN 4382 FMI 10 - NH3 sensor Heater abnormal rate of change....2859
Fault Overview....2859
Lamp Reaction....2859
Associated Faults....2859
Fault Facts....2859
Drive Cycle to Determine Fault Status....2859
Possible Causes....2859
SPN 5302 FMI 18 - Post SCR NH3 Conversion Efficiency - Data Valid But Below Normal Operating Range - Moderately Severe Level....2861
Fault Overview....2861
Lamp Reaction....2861
Associated Faults....2861
Fault Facts....2861
Drive Cycle to Determine Fault Status....2862
Possible Causes....2862
AMS (Air Management System)....2867
Overview of AMS Sensor Group....2867
Overview....2867
SPN 1209 FMI 0 - EBP above desired level....2868
Fault Overview....2868
Lamp Reaction....2868
Associated Faults....2868
Fault Facts....2868
Drive Cycle to Determine Fault Status....2868
Possible Causes....2868
SPN 1209 FMI 7 - EBP signal not responding as expected....2870
Fault Overview....2870
Lamp Reaction....2870
Associated Faults....2870
Fault Facts....2870
Drive Cycle to Determine Fault Status....2870
Possible Causes....2870
SPN 2659 FMI 10 - EGR Slow Response Fault....2872
Fault Overview....2872
Lamp Reaction....2873
Associated Faults....2873
Fault Facts....2873
Drive Cycle to Determine Fault Status....2873
Possible Causes....2873
SPN 2659 FMI 14 - EGR System Flow Rate Error During Air Management....2877
Possible Causes....2877
SPN 2659 FMI 20 - EGR High Flow Rate detected....2879
Fault Overview....2880
Lamp Reaction....2880
Associated Faults....2880
Fault Facts....2880
Drive Cycle to Determine Fault Status....2880
Possible Causes....2880
SPN 2659 FMI 21- EGR Low Flow Rate detected....2883
Fault Overview....2884
Lamp Reaction....2884
Associated Faults....2884
Fault Facts....2884
Drive Cycle to Determine Fault Status....2884
Possible Causes....2884
APP Sensor (Accelerator Pedal Position)....2888
Overview of APP Sensor Group....2888
Overview....2888
SPN 91 FMI 2 APP1 and APP2 signal conflict....2889
Fault Overview....2889
Lamp Reaction....2889
Associated Faults....2889
Fault Facts....2889
Drive Cycle to Determine Fault Status....2889
Possible Causes....2889
SPN 91 FMI 3 - APP1 signal Out of Range HIGH....2891
Fault Overview....2891
Lamp Reaction....2891
Associated Faults....2891
Fault Facts....2891
Drive Cycle to Determine Fault Status....2891
Possible Causes....2891
Pin-Point Tests (SPN 91 FMI 3)....2893
Tools Required....2893
SPN 91 FMI 4 - APP1 signal Out of Range LOW....2895
Fault Overview....2895
Lamp Reaction....2895
Associated Faults....2895
Fault Facts....2895
Drive Cycle to Determine Fault Status....2895
Possible Causes....2895
Pin-Point Tests (SPN 91 FMI 4)....2897
Tools Required....2897
SPN 2623 FMI 3 - APP2 Signal Out of Range HIGH....2902
Fault Overview....2902
Lamp Reaction....2902
Associated Faults....2902
Fault Facts....2902
Drive Cycle to Determine Fault Status....2902
Possible Causes....2902
Pin-Point Tests (SPN 2623 FMI 3)....2904
Tools Required....2904
SPN 2623 FMI 4 - APP2 Signal Out of Range LOW....2907
Fault Overview....2907
Lamp Reaction....2907
Associated Faults....2907
Fault Facts....2907
Drive Cycle to Determine Fault Status....2907
Possible Causes....2907
Pin-Point Tests (SPN 2623 FMI 4)....2909
Tools Required....2909
Body....2914
Overview of Body Sensor....2914
Overview....2914
SPN 521 FMI 2 - Brake applied while APP applied....2915
Fault Overview....2915
Lamp Reaction....2915
Associated Faults....2915
Fault Facts....2915
Drive Cycle to Determine Fault Status....2915
Possible Causes....2915
SPN 596 FMI 19 Cruise Control Enable Switch not detected on J1939....2917
Fault Overview....2917
Lamp Reaction....2917
Associated Faults....2917
Fault Facts....2917
Drive Cycle to Determine Fault Status....2917
Possible Causes....2917
SPN 597 FMI 2 - Brake switch or circuit fault....2919
Fault Overview....2919
Lamp Reaction....2919
Associated Faults....2919
Fault Facts....2919
Drive Cycle to Determine Fault Status....2919
Possible Causes....2919
SPN 597 FMI 19 - Brake switch not detected on J1939....2921
Fault Overview....2921
Lamp Reaction....2921
Associated Faults....2921
Fault Facts....2921
Drive Cycle to Determine Fault Status....2921
Possible Causes....2921
Pin-Point Tests (SPN 191 FMI 3)....2923
Tools Required....2923
CACOT Sensor (Charge Air Cooler Outlet Temperature)....2925
Overview of CACOT Sensor Group....2925
Overview....2925
SPN 2630 FMI 2 - CACOT signal erratic, intermittent, or incorrect....2926
Fault Overview....2926
Lamp Reaction....2926
Associated Faults....2926
Fault Facts....2926
Drive Cycle to Determine Fault Status....2926
Possible Causes....2926
Pin-Point Tests (SPN 2630 FMI 2)....2928
Tools Required....2928
SPN 2630 FMI 3 - CACOT Signal Out of Range HIGH....2932
Fault Overview....2932
Lamp Reaction....2932
Associated Faults....2932
Fault Facts....2932
Drive Cycle to Determine Fault Status....2932
Possible Causes....2932
Pin-Point Tests (SPN 2630 FMI 3)....2934
Tools Required....2934
SPN 2630 FMI 4 - CACOT Signal Out of Range LOW....2938
Fault Overview....2938
Lamp Reaction....2938
Associated Faults....2938
Fault Facts....2938
Drive Cycle to Determine Fault Status....2938
Possible Causes....2938
Pin-Point Tests (SPN 2630 FMI 4)....2940
Tools Required....2940
SPN 2630 FMI 16 - CACOT Undercooling....2942
Fault Overview....2942
Lamp Reaction....2942
Associated Faults....2942
Fault Facts....2942
Drive Cycle to Determine Fault Status....2942
Possible Causes....2942
CCOSS Sensor (Crankcase Oil Separator Speed)....2944
Overview of CCOSS Sensor Group....2944
Overview....2944
SPN 4227 FMI 7 - CC Oil Separator: Not spinning....2945
Fault Overview....2945
Lamp Reaction....2945
Associated Faults....2945
Fault Facts....2945
Drive Cycle to Determine Fault Status....2945
Possible Causes....2945
Pin-Point Tests (SPN 4227 FMI 7)....2947
Tools Required....2947
CKP Sensor (Crankshaft Position)....2951
Overview of CKP Sensor Group....2951
Overview....2951
SPN 637 FMI 8 - CKP signal noise....2952
Fault Overview....2952
Lamp Reaction....2952
Associated Faults....2952
Fault Facts....2952
Drive Cycle to Determine Fault Status....2952
Possible Causes....2952
SPN 637 FMI 10 - CKP signal Inactive....2954
Fault Overview....2954
Lamp Reaction....2954
Associated Faults....2954
Fault Facts....2954
Drive Cycle to Determine Fault Status....2954
Possible Causes....2954
CMP Sensor (Camshaft Position)....2956
Overview of CMP Sensor Group....2956
Overview....2956
SPN 636 FMI 2 - CMP and CKP Synchronization Error....2957
Fault Overview....2957
Lamp Reaction....2957
Associated Faults....2957
Fault Facts....2957
Drive Cycle to Determine Fault Status....2957
Possible Causes....2957
SPN 636 FMI 7 - CMP to CKP incorrect reference....2959
Fault Overview....2959
Lamp Reaction....2959
Associated Faults....2959
Fault Facts....2959
Drive Cycle to Determine Fault Status....2959
Possible Causes....2959
DCU Power (Doser Control Unit)....2961
Overview of DCU Power Sensor Group....2961
Overview....2961
SPN 609 FMI 19 - ACM not detected on J1939....2962
Fault Overview....2962
Lamp Reaction....2962
Associated Faults....2962
Fault Facts....2962
Drive Cycle to Determine Fault Status....2962
Possible Causes....2962
SPN 5109 FMI 3 - DCU battery voltage above 17 volts....2964
Fault Overview....2964
Lamp Reaction....2964
Associated Faults....2964
Fault Facts....2964
Drive Cycle to Determine Fault Status....2964
Possible Causes....2964
SPN 5109 FMI 4 - DCU battery voltage below 10 volts....2966
Fault Overview....2966
Lamp Reaction....2966
Associated Faults....2966
Fault Facts....2966
Drive Cycle to Determine Fault Status....2966
Possible Causes....2966
Pin-Point Tests (SPN 5109 FMI 4)....2968
Tools Required....2968
SPN 5109 FMI 19 - DCU not detected on J1939....2974
Fault Overview....2974
Lamp Reaction....2974
Associated Faults....2974
Fault Facts....2974
Drive Cycle to Determine Fault Status....2974
Possible Causes....2974
Pin-Point Tests (SPN 5109 FMI 19)....2976
Tools Required....2976
DEF (Diesel Exhaust Fluid)....2983
Overview of DEF Sensor Group....2983
Overview....2983
SPN 520668 FMI 31 - Controller Adaptation Outer Limits Reached (Low Reductant Delivery)....2984
Fault Overview....2984
Lamp Reaction....2985
Associated Faults....2985
Fault Facts....2985
Drive Cycle to Determine Fault Status....2985
Possible Causes....2985
SPN 520669 FMI 31 - Controller Adaptation Inner Limits Reached (Low Reductant Delivery)....2989
Fault Overview....2989
Lamp Reaction....2990
Associated Faults....2990
Fault Facts....2990
Drive Cycle to Determine Fault Status....2990
Possible Causes....2990
DEF: SMH (Diesel Exhaust Fluid Supply Module Heater)....2994
Overview of DEF: SMH Sensor Group....2994
Overview....2994
SPN 5745 FMI 3 - DEF Dosing Unit Heater Out of Range HIGH....2996
Fault Overview....2996
Lamp Reaction....2996
Associated Faults....2996
Fault Facts....2996
Drive Cycle to Determine Fault Status....2996
Possible Causes....2996
Pin-Point Tests (SPN 5745 FMI 3)....2998
Tools Required....2998
SPN 5745 FMI 4 - DEF Supply Module Heater Out of Range LOW....3002
Fault Overview....3002
Lamp Reaction....3002
Associated Faults....3002
Fault Facts....3002
Drive Cycle to Determine Fault Status....3002
Possible Causes....3002
Pin-Point Tests (SPN 5745 FMI 4)....3004
Tools Required....3004
SPN 5745 FMI 18 - DEF Supply Module Heater below Warning Temperature....3019
Fault Overview....3019
Lamp Reaction....3019
Associated Faults....3019
Fault Facts....3019
Drive Cycle to Determine Fault Status....3019
Possible Causes....3019
Pin-Point Tests (SPN 5745 FMI 18)....3021
Tools Required....3021
SPN 5798 FMI 2 - DEF Supply Module Heater Temperature erratic, intermittent or incorrect....3026
Fault Overview....3026
Lamp Reaction....3026
Associated Faults....3026
Fault Facts....3026
Drive Cycle to Determine Fault Status....3026
Possible Causes....3026
Pin-Point Tests (SPN 5798 FMI 2)....3029
Tools Required....3029
SPN 5798 FMI 10 - DEF Supply Module Heater Temperature abnormal rate of change....3033
Fault Overview....3033
Lamp Reaction....3033
Associated Faults....3033
Fault Facts....3033
Drive Cycle to Determine Fault Status....3033
Possible Causes....3033
Pin-Point Tests (SPN 5798 FMI 10) ....3036
Tools Required....3036
DEF: DU (Diesel Exhaust Fluid Doser Unit) Sensor....3040
Overview of DEF: DU Sensor Group....3040
Overview....3040
SPN 5394 FMI 2 - DEF Dosing below desired (Low NOx conversion across SCR)....3041
Fault Overview....3041
Lamp Reaction....3041
Associated Faults....3041
Fault Facts....3041
Drive Cycle to Determine Fault Status....3041
Possible Causes....3041
Pin-Point Tests (SPN 5394 FMI 2)....3043
Tools Required....3043
SPN 5394 FMI 5 - DEF Doser Valve open load/circuit....3045
Fault Overview....3045
Lamp Reaction....3045
Associated Faults....3045
Fault Facts....3045
Drive Cycle to Determine Fault Status....3045
Possible Causes....3045
Pin-Point Tests (SPN 5394 FMI 5)....3047
Tools Required....3047
SPN 5394 FMI 7 - DEF Dosing Unit - Mechanical system not responding....3054
Fault Overview....3054
Lamp Reaction....3054
Associated Faults....3054
Fault Facts....3054
Drive Cycle to Determine Fault Status....3054
Possible Causes....3054
DEF: LHR (Diesel Exhaust Fluid Line Heater Relay)....3056
Overview of DEF: LHR Sensor Group....3056
Overview....3056
SPN 5491 FMI 3 - DEF Line Heater Relay Open or short to PWR....3057
Fault Overview....3057
Lamp Reaction....3057
Associated Faults....3057
Fault Facts....3057
Drive Cycle to Determine Fault Status....3057
Possible Causes....3057
Pin-Point Tests (SPN 5491 FMI 3)....3060
Tools Required....3060
SPN 5491 FMI 4 - DEF Line Heater Relay short to GND....3068
Fault Overview....3068
Lamp Reaction....3068
Associated Faults....3068
Fault Facts....3068
Drive Cycle to Determine Fault Status....3068
Possible Causes....3068
Pin-Point Tests (SPN 5491 FMI 4)....3070
Tools Required....3070
DEF: AP (Diesel Exhaust Fluid Absolute Pressure)....3077
Overview of DEF: AP Sensor Group....3077
Overview....3077
SPN 4334 FMI 2 - DEFLP signal erratic, intermittent or incorrect....3079
Fault Overview....3079
Lamp Reaction....3079
Associated Faults....3079
Fault Facts....3079
Drive Cycle to Determine Fault Status....3079
Possible Causes....3079
SPN 4334 FMI 3 - DEFAP Signal Out of Range HIGH....3082
Fault Overview....3082
Lamp Reaction....3082
Associated Faults....3082
Fault Facts....3082
Drive Cycle to Determine Fault Status....3082
Possible Causes....3082
Pin-Point Tests (SPN 4334 FMI 3)....3084
Tools Required....3084
SPN 4334 FMI 4 - DEFAP signal Out of Range LOW....3088
Fault Overview....3088
Lamp Reaction....3088
Associated Faults....3088
Fault Facts....3088
Drive Cycle to Determine Fault Status....3088
Possible Causes....3088
Pin-Point Tests (SPN 4334 FMI 4)....3090
Tools Required....3090
SPN 4334 FMI 16 - DEF Absolute Pressure above maximum....3094
Fault Overview....3094
Lamp Reaction....3094
Associated Faults....3094
Fault Facts....3094
Drive Cycle to Determine Fault Status....3094
Possible Causes....3094
SPN 4334 FMI 18 - DEF Absolute Pressure below normal....3096
Fault Overview....3096
Lamp Reaction....3096
Associated Faults....3096
Fault Facts....3096
Drive Cycle to Determine Fault Status....3096
Possible Causes....3096
SPN 4337 FMI 2 - DEF Dosing Unit Temperature - Data Erratic, Intermittent, or Incorrect....3100
Fault Overview....3100
Lamp Reaction....3100
Associated Faults....3100
Fault Facts....3100
Drive Cycle to Determine Fault Status....3100
Possible Causes....3100
Pin-Point Tests (SPN 4337 FMI 2)....3103
Tools Required....3103
SPN 4337 FMI 10 - DEF Dosing Unit Temperature abnormal rate of change....3107
Fault Overview....3107
Lamp Reaction....3107
Associated Faults....3107
Fault Facts....3107
Drive Cycle to Determine Fault Status....3107
Possible Causes....3107
Pin-Point Tests (SPN 4337 FMI 10)....3110
Tools Required....3110
DEFSLH (Diesel Exhaust Fluid Supply Line Heater)....3115
Overview of DEFSLH Sensor Group....3115
Overview....3115
SPN 4340 FMI 3 - DEF Supply Line Heater Short to PWR....3116
Fault Overview....3116
Lamp Reaction....3116
Associated Faults....3116
Fault Facts....3116
Drive Cycle to Determine Fault Status....3116
Possible Causes....3116
Pin-Point Tests (SPN 4340 FMI 3)....3118
Tools Required....3118
SPN 4340 FMI 5 - DEF Supply Line Heater open load/circuit....3123
Fault Overview....3123
Lamp Reaction....3123
Associated Faults....3123
Fault Facts....3123
Drive Cycle to Determine Fault Status....3123
Possible Causes....3123
Pin-Point Tests (SPN 4340 FMI 5)....3127
Tools Required....3127
DEFRLH (Diesel Exhaust Fluid Return Line Heater)....3131
Overview of DEFRLH Sensor Group....3131
Overview....3131
SPN 4342 FMI 3 - DEF Return Line Heater Short to PWR....3132
Fault Overview....3132
Lamp Reaction....3132
Associated Faults....3132
Fault Facts....3132
Drive Cycle to Determine Fault Status....3132
Possible Causes....3132
Pin-Point Tests (SPN 4342 FMI 3)....3134
Tools Required....3134
SPN 4342 FMI 5 - DEF Return Line Heater open load/circuit....3139
Fault Overview....3139
Lamp Reaction....3139
Associated Faults....3139
Fault Facts....3139
Drive Cycle to Determine Fault Status....3139
Possible Causes....3139
Pin-Point Tests (SPN 4342 FMI 5)....3143
Tools Required....3143
DEF: RCV (Diesel Exhaust Fluid Return Valve)....3148
Overview of DEF: RCV Sensor Group....3148
Overview....3148
SPN 4376 FMI 3 - DEF Reverting Control Valve short to PWR....3149
Fault Overview....3149
Lamp Reaction....3149
Associated Faults....3149
Fault Facts....3149
Drive Cycle to Determine Fault Status....3149
Possible Causes....3149
Pin-Point Tests (SPN 4376 FMI 3)....3151
Tools Required....3151
SPN 4376 FMI 4 - DEF Reverting Control Valve short to GND....3155
Fault Overview....3155
Lamp Reaction....3155
Associated Faults....3155
Fault Facts....3155
Drive Cycle to Determine Fault Status....3155
Possible Causes....3155
Pin-Point Tests (SPN 4376 FMI 4)....3157
Tools Required....3157
SPN 4376 FMI 7 - DEF Reverting Control Valve - Mechanical system not responding or out of adjustment....3161
Fault Overview....3161
Lamp Reaction....3161
Associated Faults....3161
Fault Fact....3161
Drive Cycle to Determine Fault Status....3161
Possible Causes....3161
DEFPLH (Diesel Exhaust Fluid Pressure Line Heater)....3163
Overview of DEFPLH Sensor Group....3163
Overview....3163
SPN 4344 FMI 3 - DEF Pressure Line Heater Short to PWR....3164
Fault Overview....3164
Lamp Reaction....3164
Associated Faults....3164
Fault Facts....3164
Possible Causes....3164
Pin-Point Tests (SPN 4344 FMI 3)....3166
Tools Required....3166
SPN 4344 FMI 5 - DEF Pressure Line Heater open load/circuit....3170
Fault Overview....3170
Lamp Reaction....3170
Associated Faults....3170
Fault Facts....3170
Drive Cycle to Determine Fault Status....3170
Possible Causes....3170
Pin-Point Tests (SPN 4344 FMI 5)....3172
Tools Required....3172
DEF: SP (Diesel Exhaust Fluid Supply Pump)....3184
Overview of DEF: SP Sensor Group....3184
Overview....3184
SPN 3361 FMI 2 - DEFSP Signal Erratic, Intermittent or Incorrect....3186
Fault Overview....3186
Lamp Reaction....3186
Associated Faults....3186
Fault Facts....3186
Drive Cycle to Determine Fault Status....3186
Possible Causes....3186
Pin-Point Tests (SPN 3361 FMI 2)....3190
Tools Required....3190
SPN 3361 FMI 3 - DEFSP signal Out of Range HIGH....3194
Fault Overview....3194
Lamp Reaction....3194
Associated Faults....3194
Fault Facts....3194
Drive Cycle to Determine Fault Status....3194
Possible Causes....3194
Pin-Point Tests (SPN 3361 FMI 3)....3196
Tools Required....3196
SPN 3361 FMI 4 - DEFSP Signal Out of Range LOW....3199
Fault Overview....3199
Lamp Reaction....3199
Associated Faults....3199
Fault Facts....3199
Drive Cycle to Determine Fault Status....3199
Possible Causes....3199
Pin-Point Tests (SPN 3361 FMI 4)....3204
Tools Required....3204
SPN 3362 FMI 31 - DEF Dosing Unable to Prime....3208
Fault Overview....3208
Lamp Reaction....3208
Associated Faults....3208
Fault Facts....3208
Drive Cycle to Determine Fault Status....3208
DEF: THC (Diesel Exhaust Fluid Tank Heater Control) Valve....3213
Overview of DEF: THC....3213
Overview....3213
SPN 3363 FMI 3 - DEF Tank Heater Control Valve short to PWR....3215
Fault Overview....3215
Lamp Reaction....3215
Associated Faults....3215
Fault Facts....3215
Drive Cycle to Determine Fault Status....3215
Possible Causes....3215
Pin-Point Tests (SPN 3363 FMI 3)....3217
Tools Required....3217
SPN 3363 FMI 4 - DEF Tank Heater Control Valve short to GND....3221
Fault Overview....3221
Lamp Reaction....3221
Associated Faults....3221
Fault Facts....3221
Drive Cycle to Determine Fault Status....3221
Possible Causes....3221
Pin-Point Tests (SPN 3363 FMI 4)....3223
Tools Required....3223
SPN 3363 FMI 7 - DEF Tank Heater Control Valve Mechanical system not responding....3226
Fault Overview....3226
Lamp Reaction....3226
Associated Faults....3226
Drive Cycle to Determine Fault Status....3226
Possible Causes....3226
SPN 3363 FMI 16 - DEF Tank Heater Control Valve stuck open fault....3228
Fault Overview....3228
Lamp Reaction....3228
Associated Faults....3228
Fault Facts....3228
Drive Cycle to Determine Fault Status....3228
Possible Causes....3228
SPN 3363 FMI 18 - DEF Tank Heater Control Valve unable to thaw frozen DEF....3230
Fault Overview....3230
Lamp Reaction....3230
Associated Faults....3230
Fault Facts....3230
Drive Cycle to Determine Fault Status....3230
Possible Causes....3230
DEF: TL & DEF: TT (Diesel Exhaust Fluid Tank Level and Temperature) Sensor Module....3232
Overview of DEF: TL & DEF: TT Sensor Group....3232
Overview....3232
SPN 1569 FMI 31 - SCR Tamperproof Warning & Protection System Inducement Severe....3233
Fault Overview....3233
Lamp Reaction....3233
Associated Faults....3233
Fault Facts....3233
Drive Cycle to Determine Fault Status....3233
Possible Causes....3233
SPN 1761 FMI 1 - DEFTL Inducement (Level 3 - 4)....3235
Fault Overview....3235
Lamp Reaction....3235
Associated Faults....3235
Fault Facts....3235
Drive Cycle to Determine Fault Status....3235
Possible Causes....3235
SPN 1761 FMI 3 - DEFTL signal Out of Range HIGH....3237
Fault Overview....3237
Lamp Reaction....3237
Associated Faults....3237
Fault Facts....3237
Drive Cycle to Determine Fault Status....3237
Possible Causes....3237
SPN 1761 FMI 4 - DEFTL signal Out of Range LOW....3239
Fault Overview....3239
Lamp Reaction....3239
Associated Faults....3239
Fault Facts....3239
Drive Cycle to Determine Fault Status....3239
Possible Causes....3239
SPN 1761 FMI 10 - DEF Level abnormal rate of change....3241
Fault Overview....3241
Lamp Reaction....3241
Associated Faults....3241
Fault Facts....3241
Drive Cycle to Determine Fault Status....3241
Possible Causes....3241
SPN 1761 FMI 11 - DEFTL signal erratic, intermittent, or incorrect....3243
Fault Overview....3243
Lamp Reaction....3243
Associated Faults....3243
Fault Facts....3243
Drive Cycle to Determine Fault Status....3243
Possible Causes....3243
SPN 1761 FMI 17 - DEFTL Inducement Level 1....3245
Fault Overview....3245
Lamp Reaction....3245
Associated Faults....3245
Fault Facts....3245
Drive Cycle to Determine Fault Status....3245
Possible Causes....3245
SPN 1761 FMI 18 - DEFTL Inducement Level 2....3247
Fault Overview....3247
Lamp Reaction....3247
Associated Faults....3247
Fault Facts....3247
Drive Cycle to Determine Fault Status....3247
Possible Causes....3247
SPN 1761 FMI 19 - DEFTL not detected on J1939....3249
Fault Overview....3249
Lamp Reaction....3249
Associated Faults....3249
Fault Facts....3249
Drive Cycle to Determine Fault Status....3249
Possible Causes....3249
SPN 3031 FMI 2 - DEFTT signal erratic intermittent or incorrect....3251
Fault Overview....3251
Lamp Reaction....3251
Associated Faults....3251
Fault Facts....3251
Drive Cycle to Determine Fault Status....3251
Possible Causes....3251
Pin-Point Tests (SPN 3031 FMI 2)....3253
Tools Required....3253
SPN 3031 FMI 3 - DEFTT Signal Out of Range HIGH....3256
Fault Overview....3256
Lamp Reaction....3256
Associated Faults....3256
Fault Facts....3256
Drive Cycle to Determine Fault Status....3256
Possible Causes....3256
SPN 3031 FMI 4 - DEFTT signal Out of Range LOW....3258
Fault Overview....3258
Lamp Reaction....3258
Associated Faults....3258
Fault Facts....3258
Drive Cycle to Determine Fault Status....3258
Possible Causes....3258
SPN 3521 FMI 11 - Improper Reductant in DEF Tank....3260
Fault Overview....3260
Lamp Reaction....3260
Associated Faults....3260
Fault Facts....3260
Drive Cycle to Determine Fault Status....3260
Possible Causes....3260
SPN 4094 FMI 31- DEF below acceptable quality....3262
Fault Overview....3262
Lamp Reaction....3262
Associated Faults....3262
Fault Facts....3262
Drive Cycle to Determine Fault Status....3262
Possible Causes....3262
SPN 5246 FMI 15 - SCR Tamper Proof Inducement Level 1 status....3266
Fault Overview....3266
Lamp Reaction....3266
Associated Faults....3266
Fault Facts....3266
Drive Cycle to Determine Fault Status....3266
Possible Causes....3266
DEF: SMH Relay (Diesel Exhaust Fluid Supply Module Heater Relay) ....3268
Overview of DEF: SMH Relay Sensor Group....3268
Overview....3268
SPN 5746 FMI 3 - DEF Supply Module Heater Relay short to PWR....3269
Fault Overview....3269
Lamp Reaction....3269
Associated Faults....3269
Fault Facts....3269
Drive Cycle to Determine Fault Status....3269
Possible Causes....3269
Pin-Point Tests (SPN 5746 FMI 3)....3271
Tools Required....3271
SPN 5746 FMI 4 - DEF Supply Module Heater Relay short to GND....3279
Fault Overview....3279
Lamp Reaction....3279
Associated Faults....3279
Fault Facts....3279
Drive Cycle to Determine Fault Status....3279
Possible Causes....3279
Pin-Point Tests (SPN 5746 FMI 4)....3281
Tools Required....3281
DOC Temperature Sensor Module....3286
Overview of DOC / DPF Temperature Sensor Group....3286
Overview....3286
SPN 5742 FMI 3 - DPF Thermocouple Controller Out of Range HIGH....3287
Fault Overview....3287
Lamp Reaction....3287
Associated Faults....3287
Fault Facts....3287
Drive Cycle to Determine Fault Status....3287
Possible Causes....3287
Pin-Point Tests (SPN 5742 FMI 3)....3289
Tools Required....3289
SPN 5742 FMI 4 - DPF Thermocouple Controller Out of Range LOW....3292
Fault Overview....3292
Lamp Reaction....3292
Associated Faults....3292
Fault Facts....3292
Drive Cycle to Determine Fault Status....3292
Possible Causes....3292
Pin-Point Tests (SPN 5742 FMI 4)....3294
Tools Required....3294
SPN 5742 FMI 11 - DPF Thermocouple Controller signal erratic, intermittent, or incorrect....3297
Fault Overview....3297
Lamp Reaction....3297
Associated Faults....3297
Fault Facts....3297
Drive Cycle to Determine Fault Status....3297
Possible Causes....3297
Pin-Point Tests (SPN 5742 FMI 11)....3299
Tools Required....3299
SPN 5742 FMI 16 ? DPF Thermocouple Controller above Maximum Temperature....3303
Fault Overview....3303
Lamp Reaction....3303
Associated Faults....3303
Fault Facts....3303
Drive Cycle to Determine Fault Status....3303
Possible Causes....3303
SPN 5742 FMI 19 - DOC/DPF Temperature module not detect J1939....3305
Fault Overview....3305
Lamp Reaction....3305
Associated Faults....3305
Fault Facts....3305
Drive Cycle to Determine Fault Status....3305
Possible Causes....3305
Pin-Point Tests (SPN 5742 FMI 19)....3307
Tools Required....3307
DOCIT Sensor (Diesel Oxidation Catalyst Intake Temperature)....3316
Overview of DOCIT Sensor Group....3316
Overview....3316
SPN 4765 FMI 2 - DOCIT Signal erratic, intermittent, or incorrect....3317
Fault Overview....3317
Lamp Reaction....3317
Associated Faults....3317
Fault Facts....3317
Drive Cycle to Determine Fault Status....3317
Possible Causes....3317
SPN 4765 FMI 3 - DOCIT signal Out of Range HIGH....3319
Fault Overview....3319
Lamp Reaction....3319
Associated Faults....3319
Fault Facts....3319
Drive Cycle to Determine Fault Status....3319
Possible Causes....3319
SPN 4765 FMI 4 - DOCIT Signal Out of Range LOW....3321
Fault Overview....3321
Lamp Reaction....3321
Associated Faults....3321
Fault Facts....3321
Drive Cycle to Determine Fault Status....3321
Possible Causes....3321
SPN 4765 FMI 16 - DOCIT Above Maximum Temperature....3323
Fault Overview....3323
Lamp Reaction....3323
Associated Faults....3323
Fault Facts....3323
Drive Cycle to Determine Fault Status....3323
Possible Causes....3323
DPF (Diesel Particulate Filter) Sensor ....3326
Overview of DPF Sensor....3326
Overview....3326
Tools Required....3326
SPN 5397 FMI 31 - DPF regenerations are occurring too frequently....3327
Fault Overview....3327
Lamp Reaction....3327
Associated Faults....3327
Fault Facts....3327
Drive Cycle to Determine Fault Status....3327
Possible Causes....3327
DPFDP / DPFOP (Diesel Particulate Filter Differential Pressure / Diesel Particulate Filter Outlet Pressure) Sensor....3330
Overview....3330
SPN 3251 FMI 2 - DPFDP signal erratic, intermittent, or incorrect....3331
Fault Overview....3331
Lamp Reaction....3331
Associated Faults....3331
Fault Facts....3331
Drive Cycle to Determine Fault Status....3331
Possible Causes....3331
Pin-Point Tests (SPN 3251 FMI 2)....3333
Tools Required....3333
SPN 3251 FMI 3 - DPFDP signal Out of Range HIGH....3335
Fault Overview....3335
Lamp Reaction....3335
Associated Faults....3335
Fault Facts....3335
Drive Cycle to Determine Fault Status....3335
Possible Causes....3335
Pin-Point Tests (SPN 3251 FMI 3)....3337
Tools Required....3337
SPN 3251 FMI 4 - DPFDP signal Out of Range LOW....3340
Fault Overview....3340
Lamp Reaction....3340
Associated Faults....3340
Fault Facts....3340
Drive Cycle to Determine Fault Status....3340
Possible Causes....3340
Pin-Point Tests (SPN 3251 FMI 4)....3342
Tools Required....3342
SPN 3610 FMI 2 - DPFOP Signal Erratic, Intermittent, or Incorrect....3346
Fault Overview....3346
Lamp Reaction....3346
Associated Faults....3346
Fault Facts....3346
Drive Cycle to Determine Fault Status....3346
Possible Causes....3346
Pin-Point Tests (SPN 3610 FMI 2)....3348
Tools Required....3348
SPN 3610 FMI 3 - DPFOP signal Out of Range HIGH....3350
Fault Overview....3350
Lamp Reaction....3350
Associated Faults....3350
Fault Facts....3350
Drive Cycle to Determine Fault Status....3350
Possible Causes....3350
Pin-Point Tests (SPN 3610 FMI 3)....3352
Tools Required....3352
SPN 3610 FMI 4 - DPFOP Signal Out of Range LOW....3356
Fault Overview....3356
Lamp Reaction....3356
Associated Faults....3356
Fault Facts....3356
Drive Cycle to Determine Fault Status....3356
Possible Causes....3356
Pin-Point Tests (SPN 3610 FMI 4)....3358
Tools Required....3358
DPFIT Sensor (Diesel Particulate Filter Intake Temperature)....3362
Overview of DPFIT Sensor Group....3362
Overview....3362
SPN 3242 FMI 0 - DPFIT above Critical Temperature....3363
Fault Overview....3363
Lamp Reaction....3363
Associated Faults....3363
Fault Facts....3363
Drive Cycle to Determine Fault Status....3363
Possible Causes....3363
SPN 3242 FMI 2 - DPFIT signal erratic, intermittent, or incorrect....3366
Fault Overview....3366
Lamp Reaction....3366
Associated Faults....3366
Fault Facts....3366
Drive Cycle to Determine Fault Status....3366
Possible Causes....3366
SPN 3242 FMI 3 - DPFIT signal Out of Range HIGH....3368
Fault Overview....3368
Lamp Reaction....3368
Associated Faults....3368
Fault Facts....3368
Drive Cycle to Determine Fault Status....3368
Possible Causes....3368
SPN 3242 FMI 4 - DPFIT signal Out of Range LOW....3370
Fault Overview....3370
Lamp Reaction....3370
Associated Faults....3370
Fault Facts....3370
Drive Cycle to Determine Fault Status....3370
Possible Causes....3370
SPN 3242 FMI 15 - DPFIT above Warning Temperature....3372
Fault Overview....3372
Lamp Reaction....3372
Associated Faults....3372
Fault Facts....3372
Drive Cycle to Determine Fault Status....3372
Possible Causes....3372
SPN 3242 FMI 16 - DPFIT above Maximum Temperature....3375
Fault Overview....3375
Lamp Reaction....3375
Associated Faults....3375
Fault Facts....3375
Drive Cycle to Determine Fault Status....3375
Possible Causes....3375
SPN 4766 FMI 15 - DPFIT Above Warning Temperature....3378
Fault Overview....3378
Lamp Reaction....3378
Associated Faults....3378
Fault Facts....3378
Drive Cycle to Determine Fault Status....3378
Possible Causes....3378
SPN 4766 FMI 16 - DPFIT Above Maximum Temperature....3381
Fault Overview....3381
Lamp Reaction....3381
Associated Faults....3381
Fault Facts....3381
Drive Cycle to Determine Fault Status....3381
Possible Causes....3381
DPFOT Sensor (Diesel Particulate Filter Outlet Temperature)....3384
Overview of DPFOT Sensor Group....3384
Overview....3384
SPN 3246 FMI 0 - DPFOT above Critical Temperature....3385
Fault Overview....3385
Lamp Reaction....3385
Associated Faults....3385
Fault Facts....3385
Drive Cycle to Determine Fault Status....3385
Possible Causes....3385
SPN 3246 FMI 2 - DPFOT Signal Erratic, Intermittent, or Incorrect....3388
Fault Overview....3388
Lamp Reaction....3388
Associated Faults....3388
Fault Facts....3388
Drive Cycle to Determine Fault Status....3388
Possible Causes....3388
SPN 3246 FMI 3 - DPFOT signal Out of Range HIGH....3390
Fault Overview....3390
Lamp Reaction....3390
Associated Faults....3390
Fault Facts....3390
Drive Cycle to Determine Fault Status....3390
Possible Causes....3390
SPN 3246 FMI 4 - DPFOT Signal Out of Range LOW....3392
Fault Overview....3392
Lamp Reaction....3392
Associated Faults....3392
Fault Facts....3392
Drive Cycle to Determine Fault Status....3392
Possible Causes....3392
SPN 3246 FMI 15 - DPFOT above Warning Temperature....3394
Fault Overview....3394
Lamp Reaction....3394
Associated Faults....3394
Fault Facts....3394
Drive Cycle to Determine Fault Status....3394
Possible Causes....3394
SPN 3246 FMI 16 - DPFOT above Maximum Temperature....3397
Fault Overview....3397
Lamp Reaction....3397
Associated Faults....3397
Fault Facts....3397
Drive Cycle to Determine Fault Status....3397
Possible Causes....3397
EBP Sensor (Exhaust Back Pressure)....3400
Overview of EBP Sensor Group....3400
Overview....3400
SPN 1209 FMI 1 - EBP below desired level....3401
Fault Overview....3401
Lamp Reaction....3401
Associated Faults....3401
Fault Facts....3401
Drive Cycle to Determine Fault Status....3401
Possible Causes....3401
SPN 1209 FMI 2 - EBP Signal erratic, intermittent, or incorrect....3403
Fault Overview....3403
Lamp Reaction....3403
Associated Faults....3403
Fault Facts....3403
Drive Cycle to Determine Fault Status....3403
Possible Causes....3403
SPN 1209 FMI 3 - EBP Signal Out of Range HIGH....3405
Fault Overview....3405
Lamp Reaction....3405
Associated Faults....3405
Fault Facts....3405
Drive Cycle to Determine Fault Status....3405
Possible Causes....3405
Pin-Point Tests (SPN 1209 FMI 3)....3407
Tools Required....3407
SPN 1209 FMI 4 - EBP Signal Out of Range LOW....3410
Fault Overview....3410
Lamp Reaction....3410
Associated Faults....3410
Fault Facts....3410
Drive Cycle to Determine Fault Status....3410
Possible Causes....3410
Pin-Point Tests (SPN 1209 FMI 4)....3412
Tools Required....3412
EBPV (Exhaust Back Pressure Valve)....3416
Overview of EBPV Sensor Group....3416
Overview....3416
SPN 5541 FMI 2 - TC1TOP signal erratic, intermittent, or incorrect....3417
Function....3417
Lamp Reaction....3417
Associated Faults....3417
Fault Facts....3417
Drive Cycle to Determine Fault Status....3417
Possible Causes....3417
SPN 5541 FMI 3 - TC1TOP signal Out of Range HIGH....3419
Fault Overview....3419
Lamp Reaction....3419
Associated Faults....3419
Fault Facts....3419
Drive Cycle to Determine Fault Status....3419
Possible Causes....3419
Pin-Point Tests (SPN 5541 FMI 3)....3421
Tools Required....3421
SPN 5541 FMI 4 - TC1TOP signal Out of Range LOW....3428
Fault Overview....3428
Lamp Reaction....3428
Associated Faults....3428
Fault Facts....3428
Drive Cycle to Determine Fault Status....3428
Possible Causes....3428
Pin-Point Tests (SPN 5541 FMI 4)....3430
Tools Required....3430
SPN 5542 FMI 15 - TC1TOP Above Desired....3434
Fault Overview....3434
Lamp Reaction....3434
Associated Faults....3434
Fault Facts....3434
Drive Cycle to Determine Fault Status....3434
Possible Causes....3434
SPN 5542 FMI 17 - TC1TOP Below Desired....3436
Fault Overview....3436
Lamp Reaction....3436
Associated Faults....3436
Fault Facts....3436
Drive Cycle to Determine Fault Status....3436
Possible Causes....3436
SPN 5543 FMI 3 - EBPC short to PWR....3438
Fault Overview....3438
Lamp Reaction....3438
Associated Faults....3438
Fault Facts....3438
Drive Cycle to Determine Fault Status....3438
Possible Causes....3438
Pin-Point Tests (SPN 5543 FMI 3)....3440
Tools Required....3440
SPN 5543 FMI 4 - EBPC short to GND....3447
Fault Overview....3447
Lamp Reaction....3447
Associated Faults....3447
Fault Facts....3447
Drive Cycle to Determine Fault Status....3447
Possible Causes....3447
Pin-Point Tests (SPN 5543 FMI 4)....3449
Tools Required....3449
SPN 5543 FMI 5 - EBPC open load/circuit....3453
Fault Overview....3453
Lamp Reaction....3453
Associated Faults....3453
Fault Facts....3453
Drive Cycle to Determine Fault Status....3453
Possible Causes....3453
Pin-Point Tests (SPN 5543 FMI 5)....3455
Tools Required....3455
ECB1 (Engine Compression Brake Output 1)....3458
Overview of ECB1 Sensor Group....3458
Overview....3458
SPN 4287 FMI 0 - ECBP above desired level....3459
Fault Overview....3459
Lamp Reaction....3459
Associated Faults....3459
Fault Facts....3459
Drive Cycle to Determine Fault Status....3459
Possible Causes....3459
SPN 4287 FMI 1 - ECPB below desired level....3461
Fault Overview....3461
Lamp Reaction....3461
Associated Faults....3461
Fault Facts....3461
Drive Cycle to Determine Fault Status....3461
Possible Causes....3461
SPN 4287 FMI 3 - ECBP signal Out of Range HIGH....3463
Fault Overview....3463
Lamp Reaction....3463
Associated Faults....3463
Fault Facts....3463
Drive Cycle to Determine Fault Status....3463
Possible Causes....3463
Pin-Point Tests SPN 4287 FMI 3....3465
Tools Required....3465
SPN 4287 FMI 4 - ECBP signal Out of Range LOW....3473
Fault Overview....3473
Lamp Reaction....3473
Associated Faults....3473
Fault Facts....3473
Drive Cycle to Determine Fault Status....3473
Possible Causes....3473
Pin-Point Tests (SPN 4287 FMI 4)....3475
Tools Required....3475
ECI Circuit (Engine Crank Inhibit)....3478
Overview of ECI Circuit....3478
Function....3478
Location....3478
Tools....3478
ECI Circuit Diagnostics....3480
ECI Circuit Operation....3484
DDS Circuit....3484
Ignition Switch....3484
ECI Circuit....3484
Engine Control Module (ECM)....3484
Starter Relay....3484
Clutch Switch....3484
Neutral Switch....3484
WTEC MD with Auto Neutral....3484
Fault Detection / Management....3485
ECM (Engine Control Module)....3486
Overview of ECM Sensor ....3486
Overview....3486
SPN 108 FMI 2 - BARO Signal Erratic, Intermittent or Incorrect....3487
Fault Overview....3487
Lamp Reaction....3487
Associated Faults....3487
Fault Facts....3487
Drive Cycles....3487
Possible Cause....3487
SPN 108 FMI 3 - BARO signal Out of Range HIGH....3489
Fault Overview....3489
Lamp Reaction....3489
Associated Faults....3489
Fault Facts....3489
Drive Cycle to Determine Fault Status....3489
Possible Causes....3489
SPN 108 FMI 4 - BARO signal Out of Range LOW....3491
Fault Overview....3491
Lamp Reaction....3491
Associated Faults....3491
Fault Facts....3491
Drive Cycle to Determine Fault Status....3491
Possible Causes....3491
SPN 158 FMI 15 - Battery Voltage above 16 volts....3493
Fault Overview....3493
Lamp Reaction....3493
Associated Faults....3493
Fault Facts....3493
Drive Cycle to Determine Fault Status....3493
Possible Causes....3493
SPN 158 FMI 17 - Battery Voltage below 9 volts....3495
Fault Overview....3495
Lamp Reaction....3495
Associated Faults....3495
Fault Facts....3495
Drive Cycle to Determine Fault Status....3495
Possible Causes....3495
Pin-Point Tests (SPN 158 FMI 17)....3498
Tools Required....3498
SPN 628 FMI 12 - ECM Memory Error....3505
Fault Overview....3505
Lamp Reaction....3505
Associated Faults....3505
Fault Facts....3505
Drive Cycle to Determine Fault Status....3505
Possible Causes....3505
SPN 629 FMI 0 - ECM Error - CPU Load Excessively HIGH....3507
Fault Overview....3507
Lamp Reaction....3507
Associated Faults....3507
Fault Facts....3507
Drive Cycle to Determine Fault Status....3507
Possible Causes....3507
SPN 629 FMI 8 - ECM Error - Engine Off Timer fault....3509
Fault Overview....3509
Lamp Reaction....3509
Associated Faults....3509
Fault Facts....3509
Drive Cycle to Determine Fault Status....3509
Possible Causes....3509
SPN 629 FMI 12 - ECM Internal chip Error....3512
Fault Overview....3512
Lamp Reaction....3512
Associated Faults....3512
Fault Facts....3512
Drive Cycle to Determine Fault Status....3512
Possible Causes....3512
SPN 1136 FMI 0 - ECM Error - over temperature....3514
Fault Overview....3514
Lamp Reaction....3514
Associated Faults....3514
Fault Facts....3514
Drive Cycle to Determine Fault Status....3514
Possible Causes....3514
SPN 1387 FMI 31 - Altitude Reference Adder Fault....3516
Fault Overview....3516
Lamp Reaction....3516
Associated Faults....3516
Fault Facts....3517
Drive Cycle to Determine Fault Status....3517
Possible Causes....3517
ECT1 Sensor (Engine Coolant Temperature 1)....3519
Overview of ECT1 Sensor Group....3519
Overview....3519
SPN 110 FMI 2 - ECT1 signal erratic, intermittent, or incorrect....3521
Fault Overview....3521
Lamp Reaction....3521
Associated Faults....3521
Fault Facts....3521
Drive Cycle to Determine Fault Status....3521
Possible Causes....3521
Pin-Point Tests (SPN 110 FMI 2)....3523
Tools Required....3523
SPN 110 FMI 3 - ECT1 Signal Out of Range HIGH....3526
Fault Overview....3526
Lamp Reaction....3526
Associated Faults....3526
Fault Facts....3526
Drive Cycle to Determine Fault Status....3526
Possible Causes....3526
Pin-Point Tests (SPN 110 FMI 3)....3528
Tools Required....3528
SPN 110 FMI 4 - ECT1 signal Out of Range LOW....3532
Fault Overview....3532
Lamp Reaction....3532
Associated Faults....3532
Fault Facts....3532
Drive Cycle to Determine Fault Status....3532
Possible Causes....3532
Pin-Point Tests (SPN 110 FMI 4)....3534
Tools Required....3534
SPN 110 FMI 17 - ECT1 stuck in range Low....3536
Fault Overview....3536
Lamp Reaction....3537
Associated Faults....3537
Fault Facts....3537
Drive Cycle to Determine Fault Status....3537
Possible Causes....3537
Pin-Point Tests (SPN 110 FMI 17)....3538
Tools Required....3538
SPN 110 FMI 18 - Engine Coolant System below closed loop minimum Temperature....3541
Fault Overview....3542
Lamp Reaction....3542
Associated Faults....3542
Fault Facts....3542
Drive Cycle to Determine Fault Status....3542
Possible Causes....3542
Pin-Point Tests (SPN 110 FMI 17)....3544
Tools Required....3544
SPN 1659 FMI 20 - ECT1 below expected: Check Thermostat....3546
Fault Overview....3547
Lamp Reaction....3547
Associated Faults....3547
Fault Facts....3547
Drive Cycle to Determine Fault Status....3547
Possible Causes....3547
Pin-Point Tests (SPN 1659 FMI 20)....3549
Tools Required....3549
EFP (Engine Fuel Pump)....3551
Overview of EFP Group....3551
Overview....3551
SPN 94 FMI 0 - Fuel Delivery Pressure above Critical....3552
Fault Overview....3552
Lamp Reaction....3552
Associated Faults....3552
Fault Facts....3552
Drive Cycle to Determine Fault Status....3552
Possible Causes....3552
SPN 94 FMI 1 - Fuel Delivery Pressure below Critical....3554
Fault Overview....3554
Lamp Reaction....3554
Associated Faults....3554
Fault Facts....3554
Drive Cycle to Determine Fault Status....3554
Possible Causes....3554
SPN 931 FMI 3 - EFP short to PWR....3556
Fault Overview....3556
Lamp Reaction....3556
Associated Faults....3556
Fault Facts....3556
Drive Cycle to Determine Fault Status....3556
Possible Causes....3556
SPN 931 FMI 4 - EFP open load / circuit or short to GND....3558
Fault Overview....3558
Lamp Reaction....3558
Associated Faults....3558
Fault Facts....3558
Drive Cycle to Determine Fault Status....3558
Possible Causes....3558
EGR Actuator (Exhaust Gas Recirculation)....3560
Overview of EGR Actuator Sensor Group....3560
Overview....3560
SPN 27 FMI 0 - EGRP fault: over temperature....3562
Fault Overview....3562
Lamp Reaction....3562
Associated Faults....3562
Fault Facts....3562
Drive Cycle to Determine Fault Status....3562
Possible Causes....3562
SPN 27 FMI 14 - EGR internal circuit failure....3564
Fault Overview....3564
Lamp Reaction....3564
Associated Faults....3564
Fault Facts....3564
Drive Cycle to Determine Fault Status....3564
Possible Causes....3564
SPN 2791 FMI 2 - EGR feedback communication fault....3566
Fault Overview....3566
Lamp Reaction....3566
Associated Faults....3566
Fault Facts....3566
Drive Cycle to Determine Fault Status....3566
Possible Causes....3566
Pin-Point Tests (SPN 2791 FMI 2)....3568
Tools Required....3568
SPN 2791 FMI 3 - EGRV supply voltage is too HIGH....3575
Fault Overview....3575
Lamp Reaction....3575
Associated Faults....3575
Fault Facts....3575
Drive Cycle to Determine Fault Status....3575
Possible Causes....3575
SPN 2791 FMI 4 - EGRV supply voltage is too LOW....3577
Fault Overview....3577
Lamp Reaction....3577
Associated Faults....3577
Fault Facts....3577
Drive Cycle to Determine Fault Status....3577
Possible Causes....3577
Pin-Point Tests (SPN 2791 FMI 4)....3579
Tools Required....3579
SPN 2791 FMI 7 - EGR Valve unable to achieve commanded position....3581
Fault Overview....3581
Lamp Reaction....3581
Associated Faults....3581
Fault Facts....3581
Drive Cycle to Determine Fault Status....3581
Possible Causes....3581
SPN 2791 FMI 8 - EGR valve not receiving ECM PWM signal....3583
Fault Overview....3583
Lamp Reaction....3583
Associated Faults....3583
Fault Facts....3583
Drive Cycle to Determine Fault Status....3583
Possible Causes....3583
Pin-Point Tests (SPN 2791 FMI 8)....3585
Tools Required....3585
SPN 2791 FMI 12 - EGR Valve Internal self test fault....3592
Fault Overview....3592
Lamp Reaction....3592
Associated Fault....3592
Fault Facts....3592
Drive Cycle to Determine Fault Status....3592
Possible Causes....3592
SPN 2791 FMI 14 - EGR Valve did not seat....3594
Fault Overview....3594
Lamp Reaction....3594
Associated Fault....3594
Fault Facts....3594
Drive Cycle to Determine Fault Status....3594
Possible Causes....3594
SPN 4752 FMI 4 - EGR Cooler Efficiency: EGR Outlet Temp above expected....3596
Fault Overview....3598
Lamp Reaction....3598
Associated Faults....3598
Fault Facts....3598
Drive Cycle to Determine Fault Status....3598
Possible Causes....3598
EGT Sensor (Exhaust Gas Temperature)....3601
Overview of EGT Sensor Group....3601
Overview....3601
SPN 173 FMI 2 - EGT signal erratic, intermittent, or incorrect....3603
Fault Overview....3603
Lamp Reaction....3603
Associated Faults....3603
Fault Facts....3603
Drive Cycle to Determine Fault Status....3603
Possible Causes....3603
Pin-Point Tests (SPN 173 FMI 2)....3605
Tools Required....3605
SPN 173 FMI 3 - EGT Signal Out of Range HIGH....3608
Fault Overview....3608
Lamp Reaction....3608
Associated Faults....3608
Fault Facts....3608
Drive Cycle to Determine Fault Status....3608
Possible Causes....3608
Pin-Point Tests (SPN 173 FMI 3)....3610
Tools Required....3610
SPN 173 FMI 4 - EGT Signal Out of Range LOW....3615
Fault Overview....3615
Lamp Reaction....3615
Associated Faults....3615
Fault Facts....3615
Drive Cycle to Determine Fault Status....3615
Possible Causes....3615
Pin-Point Tests (SPN 173 FMI 4)....3616
Tools Required....3616
Engine....3618
Overview of Engine Sensor ....3618
SPN 188 FMI 0 - Engine Low Idle RPM above normal....3619
Fault Overview....3619
Lamp Reaction....3619
Associated Faults....3619
Fault Facts....3619
Drive Cycle to Determine Fault Status....3619
Possible Causes....3619
SPN 188 FMI 1 - Engine Low Idle RPM below normal....3621
Fault Overview....3621
Lamp Reaction....3621
Associated Faults....3621
Fault Facts....3621
Drive Cycle to Determine Fault Status....3621
Possible Causes....3621
SPN 1322 FMI 31 Misfire - Multiple Cylinders....3624
Fault Overview....3624
Lamp Reaction....3624
Associated Faults....3625
Fault Facts....3625
Drive Cycle to Determine Fault Status....3625
Possible Causes....3625
SPN 5395 FMI 0 Engine unable to achieve desired idle torque (too high)....3627
Fault Overview....3627
Lamp Reaction....3627
Associated Faults....3627
Fault Facts....3627
Drive Cycle to Determine Fault Status....3627
Possible Causes....3627
SPN 5395 FMI 1 Engine unable to achieve desired idle torque (too low)....3631
Fault Overview....3631
Lamp Reaction....3631
Associated Faults....3631
Fault Facts....3631
Drive Cycle to Determine Fault Status....3631
Possible Causes....3631
SPN 1323 -1328 FMI 31 - Misfire - Cylinder 1 (through 6)....3635
Fault Overview....3636
Lamp Reaction....3636
Associated Faults....3636
Fault Facts....3636
Drive Cycle to Determine Fault Status....3636
Possible Causes....3636
EOP Sensor (Engine Oil Pressure)....3638
Overview of EOP Sensor Group....3638
Overview....3638
SPN 100 FMI 3 - EOP signal Out of Range HIGH....3639
Fault Overview....3639
Lamp Reaction....3639
Associated Faults....3639
Fault Facts....3639
Drive Cycle to Determine Fault Status....3639
Possible Causes....3639
Pin-Point Tests (SPN 100 FMI 3)....3641
Tools Required....3641
SPN 100 FMI 4 - EOP Signal Out of Range LOW....3643
Fault Overview....3643
Lamp Reaction....3643
Associated Faults....3643
Fault Facts....3643
Drive Cycle to Determine Fault Status....3643
Possible Causes....3643
Pin-Point Tests (SPN 100 FMI 4)....3645
Tools Required....3645
EOT Sensor (Engine Oil Temperature)....3649
Overview of EOT Sensor Group....3649
Overview....3649
SPN 175 FMI 2 - EOT signal erratic, intermittent, or incorrect....3651
Fault Overview....3651
Lamp Reaction....3651
Associated Faults....3651
Fault Facts....3651
Drive Cycle to Determine Fault Status....3651
Possible Causes....3651
Pin-Point Tests (SPN 175 FMI 2)....3653
Tools Required....3653
SPN 175 FMI 3 - EOT signal Out of Range HIGH....3656
Fault Overview....3656
Lamp Reaction....3656
Associated Faults....3656
Fault Facts....3656
Drive Cycle to Determine Fault Status....3656
Possible Causes....3656
Pin-Point Tests (SPN 175 FMI 3)....3659
Tools Required....3659
SPN 175 FMI 4 - EOT signal Out of Range LOW....3663
Fault Overview....3663
Lamp Reaction....3663
Associated Faults....3663
Fault Facts....3663
Drive Cycle to Determine Fault Status....3663
Possible Causes....3663
Pin-Point Tests (SPN 175 FMI 4)....3665
Tools Required....3665
SPN 175 FMI 7 - EOT not warming along with engine....3667
Fault Overview....3667
Lamp Reaction....3667
Associated Faults....3667
Fault Facts....3667
Drive Cycle to Determine Fault Status....3667
Possible Causes....3667
Pin-Point Tests (SPN 175 FMI 7)....3669
Tools Required....3669
ETP (Engine Throttle Valve Position)....3673
Overview of ETP Sensor Group....3673
Overview....3673
SPN 51 FMI 3 - ETP signal Out of Range HIGH....3675
Fault Overview....3675
Lamp Reaction....3675
Associated Faults....3675
Drive Cycle to Determine Fault Status....3675
Possible Causes....3675
SPN 51 FMI 4 - ETP signal Out of Range LOW....3678
Fault Overview....3678
Lamp Reaction....3678
Associated Faults....3678
Fault Facts....3678
Drive Cycle to Determine Fault Status....3678
Possible Causes....3678
Pin-Point Tests (SPN 51 FMI 4)....3680
Tools Required....3680
SPN 51 FMI 7 - ETP does not agree with commanded position....3684
Fault Overview....3684
Lamp Reaction....3684
Associated Faults....3684
Fault Facts....3684
Drive Cycle to Determine Fault Status....3684
Possible Causes....3684
Pin-Point Tests (SPN 51 FMI 7)....3686
Tools Required....3686
SPN 3464 FMI 31 - Intake Throttle Valve short circuit fault....3688
Fault Overview....3688
Lamp Reaction....3688
Associated Faults....3688
Fault Facts....3688
Drive Cycle to Determine Fault Status....3688
Possible Causes....3688
Pin-Point Tests (SPN 3464 FMI 31)....3690
Tools Required....3690
EWPS (Engine Warning Protection System)....3696
Overview of EWPS Sensor Group....3696
Overview....3696
Standard Warning....3696
3-way Warning....3696
3-way Protection....3696
Warning (Amber Triangle Light):....3697
Critical (Exclamation Mark Stop Lamp):....3697
Event log (if equipped):....3697
EWPS Programmable Parameters....3697
ECT Warning Temperature:....3697
ECT Critical Temperature:....3697
EOP Engine Speed Region Boundary 1 (600 RPM):....3697
EOP Engine Speed Region Boundary 2 (800 RPM):....3697
EOP Engine Speed Region Boundary 3 (1000 RPM):....3697
EOP Warning Pressure for Region 1 (10 psi / 69 kPa):....3697
EOP Warning pressure for Region 2 (16 psi / 110 kPa):....3697
EOP Warning Pressure for Region 3 (20 psi / 138 kPa):....3698
EOP Critical Pressure for Region 1 (7.5 psi / 52 kPa):....3698
EOP Critical Pressure for Region 2 (12 psi / 83 kPa):....3698
EOP Critical Pressure for Region 3. (15 psi / 103 kPa):....3698
SPN 100 FMI 1 - Engine Oil System below Critical Pressure....3699
Fault Overview....3699
Associated Faults....3699
Fault Facts....3699
Drive Cycle to Determine Fault Status....3699
Possible Causes....3699
SPN 100 FMI 18 - Engine Oil System below Warning Pressure....3701
Fault Overview....3701
Associated Faults....3701
Fault Facts....3701
Drive Cycle to Determine Fault Status....3701
Possible Causes....3701
SPN 110 FMI 0 - Engine Cooling System above Critical Temperature....3703
Fault Overview....3703
Lamp Reaction....3703
Associated Faults....3703
Fault Facts....3703
Drive Cycle to Determine Fault Status....3703
Possible Causes....3703
SPN 110 FMI 15 - Engine Cooling System above Warning Temperature....3705
Fault Overview....3705
Lamp Reaction....3705
Associated Faults....3705
Fault Facts....3705
Drive Cycle to Determine Fault Status....3705
Possible Causes....3705
SPN 110 FMI 16 - ECT1 stuck in range High....3707
Fault Overview....3708
Lamp Reaction....3708
Associated Faults....3708
Fault Facts....3708
Drive Cycle to Determine Fault Status....3708
Possible Causes....3708
SPN 111 FMI 1 - ECL Below Warning / Critical Level....3710
Fault Overview....3710
Lamp Reaction....3710
Associated Faults....3710
Fault Facts....3710
Drive Cycle to Determine Fault Status....3710
Possible Causes....3710
Pin-Point Tests (SPN 111 FMI 31)....3712
Tools Required....3712
SPN 111 FMI 2 - ECL signal erratic, intermittent, or incorrect....3714
Fault Overview....3714
Lamp Reaction....3714
Associated Faults....3714
Fault Facts....3714
Drive Cycle to Determine Fault Status....3714
Possible Causes....3714
SPN 175 FMI 15 - Engine Oil System above Warning Temperature....3716
Fault Overview....3716
Lamp Reaction....3716
Associated Faults....3716
Fault Facts....3716
Drive Cycle to Determine Fault Status....3716
Possible Causes....3716
Pin-Point Tests (SPN 175 FMI 15)....3718
Tools Required....3718
SPN 190 FMI 0 - Engine overspeed - Most Severe Level....3722
Fault Overview....3722
Lamp Reaction....3722
Associated Faults....3722
Fault Facts....3722
Drive Cycle to Determine Fault Status....3722
Possible Causes....3722
SPN 593 FMI 31 - Engine Stopped by IST....3725
Function....3725
Tools....3725
Idle Shutdown Warning....3725
Engine Idle Shutdown Timer (IST) for California ESS Compliant Engines....3725
CARB Idle Shutdown Timer (IST) Conditions....3726
Idle Shutdown Timer (IST) (Federal ? Optional)....3726
Federal IST Conditions....3726
Common Enable Conditions for All Federal IST Options....3726
Federal IST Mode 1: PTO Operation Option Enable Conditions....3727
Federal IST Mode 2: No Load / Light Load Limit Option Enable Conditions....3727
Federal IST Mode 3: Tamper Proof Option Enable Conditions....3727
Fault Detection / Management....3727
SPN 1378 FMI 31 - Change Engine Oil Service Interval....3728
Fault Overview....3728
Lamp Reaction....3728
Associated Faults....3728
Fault Facts....3728
Drive Cycle to Determine Fault Status....3728
Possible Causes....3728
SPN 3936 FMI 0 - DPF Soot Load ? Severe De-Rate....3729
Fault Overview....3729
Lamp Reaction....3729
Associated Faults....3729
Fault Facts....3729
Drive Cycle to Determine Fault Status....3729
Possible Causes....3729
FDP (Fuel Delivery Pressure) Sensor....3733
Overview of FDP Sensor Group....3733
Overview....3733
SPN 94 FMI 3 - FDP signal Out of Range HIGH....3735
Fault Overview....3735
Lamp Reaction....3735
Associated Faults....3735
Fault Facts....3735
Drive Cycle to Determine Fault Status....3735
Possible Causes....3735
Pin-Point Tests (SPN 94 FMI 3)....3737
Tools Required....3737
SPN 94 FMI 4 - FDP signal Out of Range LOW....3740
Fault Overview....3740
Lamp Reaction....3740
Associated Faults....3740
Fault Facts....3740
Drive Cycle to Determine Fault Status....3740
Possible Causes....3740
Pin-Point Tests (SPN 94 FMI 4)....3742
Tools Required....3742
SPN 94 FMI 17 - Fuel Delivery Pressure below minimum....3747
Fault Overview....3747
Lamp Reaction....3747
Associated Faults....3747
Fault Facts....3747
Drive Cycle to Determine Fault Status....3747
Possible Causes....3747
SPN 94 FMI 18 - Fuel Delivery Pressure below min during cranking....3749
Fault Overview....3749
Lamp Reaction....3749
Associated Faults....3749
Fault Facts....3749
Drive Cycles....3749
Possible Causes....3749
FLI (Fuel Level Signal)....3751
Overview of FLI Sensor Group....3751
Overview....3751
SPN 96 FMI 3 - Fuel Level signal Out of Range HIGH....3752
Fault Overview....3752
Lamp Reaction....3752
Associated Faults....3752
Fault Facts....3752
Drive Cycle to Determine Fault Status....3752
Possible Causes....3752
SPN 96 FMI 4 - Fuel Level signal Out of Range LOW....3754
Fault Overview....3754
Lamp Reaction....3754
Associated Faults....3754
Fault Facts....3754
Drive Cycle to Determine Fault Status....3754
Possible Causes....3754
SPN 96 FMI 19 - Fuel Level not detected on J1939....3756
Fault Overview....3756
Lamp Reaction....3756
Associated Faults....3756
Fault Facts....3756
Drive Cycle to Determine Fault Status....3756
Possible Causes....3756
IAHC (Intake Air Heater Control)....3758
Overview of IAHC Group....3758
Overview....3758
SPN 729 FMI 3 - IAHC short to PWR....3759
Fault Overview....3759
Lamp Reaction....3759
Associated Faults....3759
Fault Facts....3759
Drive Cycle to Determine Fault Status....3759
Possible Causes....3759
Pin-Point Tests (SPN 729 FMI 3)....3761
Tools Required....3761
SPN 729 FMI 4 - IAHC short to GND....3763
Fault Overview....3763
Lamp Reaction....3763
Associated Faults....3763
Fault Facts....3763
Drive Cycle to Determine Fault Status....3763
Possible Causes....3763
SPN 729 FMI 5 - IAHC open load / circuit....3765
Fault Overview....3765
Lamp Reaction....3765
Associated Faults....3765
Fault Facts....3765
Drive Cycle to Determine Fault Status....3765
Possible Causes....3765
Pin-Point Tests (SPN 729 FMI 5)....3767
Tools Required....3767
SPN 729 FMI 18 - IAH Monitor fault: Lack of Heat in the Intake Manifold....3770
Fault Overview....3770
Lamp Reaction....3770
Associated Faults....3770
Fault Facts....3770
Drive Cycle to Determine Fault Status....3770
Possible Causes....3770
ICP Sensor (Injection Control Pressure)....3772
Overview of ICP Sensor Group....3772
Overview....3772
SPN 164 FMI 0 - ICP above KOEO Specification....3773
Fault Overview....3773
Lamp Reaction....3773
Associated Faults....3773
Fault Facts....3773
Drive Cycle to Determine Fault Status....3773
Possible Causes....3773
SPN 164 FMI 1 - ICP Unable to Build During Engine Cranking....3775
Fault Overview....3775
Lamp Reaction....3775
Associated Faults....3775
Fault Facts....3775
Drive Cycle to Determine Fault Status....3775
Possible Causes....3775
SPN 164 FMI 3 - ICP signal Out of Range HIGH....3777
Fault Overview....3777
Lamp Reaction....3777
Associated Faults....3777
Fault Facts....3777
Drive Cycle to Determine Fault Status....3777
Possible Causes....3777
Pin-Point Tests (SPN 164 FMI 3)....3779
Tools Required....3779
SPN 164 FMI 4 - ICP signal Out of Range LOW....3787
Fault Overview....3787
Lamp Reaction....3787
Associated Faults....3787
Fault Facts....3787
Drive Cycle to Determine Fault Status....3787
Possible Causes....3787
Pin-Point Tests (SPN 164 FMI 4)....3789
Tools Required....3789
SPN 164 FMI 15 - ICP too high during test....3792
Fault Overview....3792
Lamp Reaction....3792
Associated Faults....3792
Fault Facts....3792
Drive Cycle to Determine Fault Status....3792
Possible Causes....3792
SPN 164 FMI 16 - ICP above desired level....3795
Fault Overview....3796
Lamp Reaction....3796
Associated Faults....3796
Fault Facts....3796
Drive Cycle to Determine Fault Status....3796
Possible Causes....3796
SPN 164 FMI 17 - ICP unable to build during test....3800
Fault Overview....3800
Lamp Reaction....3800
Associated Faults....3800
Fault Facts....3800
Drive Cycle to Determine Fault Status....3800
Possible Causes....3800
SPN 164 FMI 18 - ICP below desired level....3804
Fault Overview....3805
Lamp Reaction....3805
Associated Faults....3805
Fault Facts....3805
Drive Cycle to Determine Fault Status....3805
Possible Causes....3805
IMP (Intake Manifold Pressure)....3808
Overview of IMP Sensor Group....3808
Overview....3808
SPN 102 FMI 2 - IMP signal erratic, intermittent, or incorrect....3809
Fault Overview....3809
Lamp Reaction....3809
Associated Faults....3809
Fault Facts....3809
Drive Cycle to Determine Fault Status....3810
Possible Causes....3810
SPN 102 FMI 3 - IMP signal Out of Range HIGH....3812
Fault Overview....3812
Lamp Reaction....3812
Associated Faults....3812
Fault Facts....3812
Drive Cycle to Determine Fault Status....3812
Possible Causes....3812
Pin-Point Tests (SPN 102 FMI 3)....3814
Tools Required....3814
SPN 102 FMI 4 - IMP signal Out of Range LOW....3817
Fault Overview....3817
Lamp Reaction....3817
Associated Faults....3817
Fault Facts....3817
Drive Cycle to Determine Fault Status....3817
Possible Causes....3817
Pin-Point Tests (SPN 102 FMI 4)....3819
Tools Required....3819
SPN 102 FMI 7 - IMP signal not responding as expected....3823
Fault Overview....3824
Lamp Reaction....3824
Associated Faults....3824
Fault Facts....3824
Drive Cycle to Determine Fault Status....3824
Possible Causes....3824
SPN 102 FMI 10 - Boost slow response fault....3826
Fault Overview....3827
Lamp Reaction....3827
Associated Faults....3827
Fault Facts....3827
Drive Cycle to Determine Fault Status....3827
Possible Causes....3827
SPN 102 FMI 16 - Overboost....3829
Fault Overview....3829
Lamp Reaction....3829
Associated Faults....3830
Fault Facts....3830
Drive Cycle to Determine Fault Status....3830
Possible Causes....3830
SPN 102 FMI 18 - Underboost....3832
Fault Overview....3833
Lamp Reaction....3833
Associated Faults....3833
Fault Facts....3833
Drive Cycle to Determine Fault Status....3833
Possible Causes....3833
IMT Sensor (Intake Manifold Temperature)....3835
Overview of IMT Sensor Group....3835
Overview....3835
SPN 105 FMI 2 - IMT signal Erratic, Intermittent, or Incorrect....3836
Fault Overview....3836
Lamp Reaction....3836
Associated Faults....3836
Fault Facts....3836
Drive Cycle to Determine Fault Status....3836
Possible Causes....3836
Pin-Point Tests (SPN 105 FMI 2)....3838
Tools Required....3838
SPN 105 FMI 3 - IMT signal Out of Range HIGH....3841
Fault Overview....3841
Lamp Reaction....3841
Associated Faults....3841
Fault Facts....3841
Drive Cycle to Determine Fault Status....3841
Possible Causes....3841
Pin-Point Tests (SPN 105 FMI 3)....3843
Tools Required....3843
SPN 105 FMI 4 - IMT signal Out of Range LOW....3847
Fault Overview....3847
Lamp Reaction....3847
Associated Faults....3847
Fault Facts....3847
Drive Cycle to Determine Fault Status....3847
Possible Causes....3847
Pin-Point Tests (SPN 105 FMI 4)....3849
Tools Required....3849
INJ (Injector) Circuits....3851
Overview of INJ Sensor Group....3851
Overview....3852
SPN 651 FMI 4 - Injector 1 open coil - short circuit....3853
Fault Overview....3853
Lamp Reaction....3853
Associated Faults....3853
Fault Facts....3853
Drive Cycle to Determine Fault Status....3853
Possible Causes....3853
Pin-Point Tests (SPN 651 FMI 4)....3855
Tools Required....3855
SPN 652 FMI 4 - Injector 2 open coil - short circuit....3862
Fault Overview....3862
Lamp Reaction....3862
Associated Faults....3862
Fault Facts....3862
Drive Cycle to Determine Fault Status....3862
Possible Causes....3862
Pin-Point Tests (SPN 652 FMI 4)....3864
Tools Required....3864
SPN 653 FMI 4 - Injector 3 open coil - short circuit....3871
Fault Overview....3871
Lamp Reaction....3871
Associated Faults....3871
Fault Facts....3871
Drive Cycle to Determine Fault Status....3871
Possible Causes....3871
Pin-Point Tests (SPN 653 FMI 4)....3873
Tools Required....3873
SPN 654 FMI 4 - Injector 4 open coil - short circuit....3880
Fault Overview....3880
Lamp Reaction....3880
Associated Faults....3880
Fault Facts....3880
Drive Cycle to Determine Fault Status....3880
Possible Causes....3880
Pin-Point Tests (SPN 654 FMI 4)....3882
Tools Required....3882
SPN 655 FMI 4 - Injector 5 open coil - short circuit....3889
Fault Overview....3889
Lamp Reaction....3889
Associated Faults....3889
Fault Facts....3889
Drive Cycle to Determine Fault Status....3889
Possible Causes....3889
Pin-Point Tests (SPN 655 FMI 4)....3891
Tools Required....3891
SPN 656 FMI 4 - Injector 6 open coil - short circuit....3898
Fault Overview....3898
Lamp Reaction....3898
Associated Faults....3898
Fault Facts....3898
Drive Cycle to Determine Fault Status....3898
Possible Causes....3898
Pin-Point Tests (SPN 656 FMI 4)....3900
Tools Required....3900
SPN 651 FMI 5 - Injector 1 open coil - open circuit....3907
Fault Overview....3907
Lamp Reaction....3907
Associated Faults....3907
Fault Facts....3907
Drive Cycle to Determine Fault Status....3907
Possible Causes....3907
Pin-Point Tests (SPN 651 FMI 5)....3909
Tools Required....3909
SPN 652 FMI 5 - Injector 2 open coil - open circuit....3914
Fault Overview....3914
Lamp Reaction....3914
Associated Faults....3914
Fault Facts....3914
Drive Cycle to Determine Fault Status....3914
Possible Causes....3914
Pin-Point Tests (SPN 652 FMI 5)....3917
Tools Required....3917
SPN 653 FMI 5 - Injector 3 open coil - open circuit....3922
Fault Overview....3922
Lamp Reaction....3922
Associated Faults....3922
Fault Facts....3922
Drive Cycle to Determine Fault Status....3922
Possible Causes....3922
Pin-Point Tests (SPN 653 FMI 5)....3924
Tools Required....3924
SPN 654 FMI 5 - Injector 4 open coil - open circuit....3929
Fault Overview....3929
Lamp Reaction....3929
Associated Faults....3929
Fault Facts....3929
Drive Cycle to Determine Fault Status....3929
Possible Causes....3929
Pin-Point Tests (SPN 654 FMI 5)....3931
Tools Required....3931
SPN 655 FMI 5 - Injector 5 open coil - open circuit....3936
Fault Overview....3936
Lamp Reaction....3936
Associated Faults....3936
Fault Facts....3936
Drive Cycle to Determine Fault Status....3936
Possible Causes....3936
Pin-Point Tests (SPN 655 FMI 5)....3938
Tools Required....3938
SPN 656 FMI 5 - Injector 6 open coil - open circuit....3943
Fault Overview....3943
Lamp Reaction....3943
Associated Faults....3943
Fault Facts....3943
Drive Cycle to Determine Fault Status....3943
Possible Causes....3943
Pin-Point Tests (SPN 656 FMI 5)....3945
Tools Required....3945
SPN 651 - 656 FMI 7 - Injector 1 (through 6) Spool Motion Compensation Max Authority Reached....3951
Fault Overview....3951
Lamp Reaction....3951
Associated Faults....3951
Fault Facts....3951
Drive Cycle to Determine Fault Status....3951
Possible Causes....3951
SPN 651 FMI 14 - Injector 1 Fuel quantity/timing error....3953
Fault Overview....3955
Lamp Reaction....3955
Associated Faults....3955
Fault Facts....3955
Drive Cycle to Determine Fault Status....3955
Possible Causes....3955
Pin-Point Tests (SPN 651 FMI 14)....3960
Tools Required....3960
SPN 652 FMI 14 - Injector 2 Fuel quantity/timing error....3970
Fault Overview....3970
Lamp Reaction....3970
Associated Faults....3970
Fault Facts....3970
Drive Cycle to Determine Fault Status....3971
Possible Causes....3971
Pin-Point Tests (SPN 652 FMI 14)....3976
Tools Required....3976
SPN 653 FMI 14 - Injector 3 Fuel quantity/timing error....3987
Fault Overview....3987
Lamp Reaction....3987
Associated Faults....3987
Fault Facts....3987
Drive Cycle to Determine Fault Status....3987
Possible Causes....3987
Pin-Point Tests (SPN 653 FMI 14)....3992
Tools Required....3992
SPN 654 FMI 14 - Injector 4 Fuel quantity/timing error....4003
Fault Overview....4003
Lamp Reaction....4003
Associated Faults....4003
Fault Facts....4003
Drive Cycle to Determine Fault Status....4003
Possible Causes....4003
Pin-Point Tests (SPN 654 FMI 14)....4008
Tools Required....4008
SPN 655 FMI 14 - Injector 5 Fuel quantity/timing error....4019
Fault Overview....4019
Lamp Reaction....4019
Associated Faults....4019
Fault Facts....4019
Drive Cycle to Determine Fault Status....4019
Possible Causes....4019
Pin-Point Tests (SPN 655 FMI 14)....4024
Tools Required....4024
SPN 656 FMI 14 - Injector 6 Fuel quantity/timing error....4035
Fault Overview....4035
Lamp Reaction....4035
Associated Faults....4035
Fault Facts....4035
Drive Cycle to Determine Fault Status....4035
Possible Causes....4035
Pin-Point Tests (SPN 656 FMI 14)....4040
Tools Required....4040
SPN 2797 FMI 6 - Injector Control Group 1 - short circuit (INJ 1, 2, 3)....4051
Fault Overview....4051
Lamp Reaction....4051
Associated Faults....4051
Fault Facts....4051
Drive Cycle to Determine Fault Status....4051
Possible Causes....4051
Pin-Point Tests (SPN 2797 FMI 6)....4055
Tools Required....4055
SPN 2798 FMI 6 - Injector Control Group 2 - short circuit (INJ 4, 5, 6)....4097
Fault Overview....4097
Lamp Reaction....4097
Associated Faults....4097
Fault Facts....4097
Drive Cycle to Determine Fault Status....4097
Possible Causes....4098
Pin-Point Tests (SPN 2798 FMI 6)....4101
Tools Required....4101
SPN 3055 FMI 2 - ICP / IPR Adaptation In-Range Fault....4143
Fault Overview....4143
Lamp Reaction....4143
Associated Faults....4143
Fault Facts....4143
Drive Cycle to Determine Fault Status....4143
Possible Causes....4143
SPN 3659 FMI 4 - Injector 1 close coil ? short circuit....4147
Fault Overview....4147
Lamp Reaction....4147
Associated Faults....4147
Fault Facts....4147
Drive Cycle to Determine Fault Status....4147
Possible Causes....4147
Pin-Point Tests (SPN 3659 FMI 4)....4149
Tools Required....4149
SPN 3660 FMI 4 - Injector 2 close coil ? short circuit....4156
Fault Overview....4156
Lamp Reaction....4156
Associated Faults....4156
Fault Facts....4156
Drive Cycle to Determine Fault Status....4156
Possible Causes....4156
Pin-Point Tests (SPN 3660 FMI 4)....4158
Tools Required....4158
SPN 3661 FMI 4 - Injector 3 close coil ? short circuit....4165
Fault Overview....4165
Lamp Reaction....4165
Associated Faults....4165
Fault Facts....4165
Drive Cycle to Determine Fault Status....4165
Possible Causes....4165
Pin-Point Tests (SPN 3661 FMI 4)....4167
Tools Required....4167
SPN 3662 FMI 4 - Injector 4 close coil ? short circuit....4174
Fault Overview....4174
Lamp Reaction....4174
Associated Faults....4174
Fault Facts....4174
Drive Cycle to Determine Fault Status....4174
Possible Causes....4174
Pin-Point Tests (SPN 3662 FMI 4)....4176
Tools Required....4176
SPN 3663 FMI 4 - Injector 5 close coil ? short circuit....4183
Fault Overview....4183
Lamp Reaction....4183
Associated Faults....4183
Fault Facts....4183
Drive Cycle to Determine Fault Status....4183
Possible Causes....4183
Pin-Point Tests (SPN 3663 FMI 4)....4185
Tools Required....4185
SPN 3664 FMI 4 - Injector 6 close coil ? short circuit....4192
Fault Overview....4192
Lamp Reaction....4192
Associated Faults....4192
Fault Facts....4192
Drive Cycle to Determine Fault Status....4192
Possible Causes....4192
Pin-Point Tests (SPN 3664 FMI 4)....4194
Tools Required....4194
SPN 3659 FMI 5 - Injector 1 close coil ? open circuit....4201
Fault Overview....4201
Lamp Reaction....4201
Associated Faults....4201
Fault Facts....4201
Drive Cycle to Determine Fault Status....4201
Possible Causes....4201
Pin-Point Tests (SPN 3659 FMI 5)....4203
Tools Required....4203
SPN 3660 FMI 5 - Injector 2 close coil ? open circuit....4208
Fault Overview....4208
Lamp Reaction....4208
Associated Faults....4208
Fault Facts....4208
Drive Cycle to Determine Fault Status....4208
Possible Causes....4208
Pin-Point Tests (SPN 3660 FMI 5)....4210
Tools Required....4210
SPN 3661 FMI 5 - Injector 3 close coil ? open circuit....4215
Fault Overview....4215
Lamp Reaction....4215
Associated Faults....4215
Fault Facts....4215
Drive Cycle to Determine Fault Status....4215
Possible Causes....4215
Pin-Point Tests (SPN 3661 FMI 5)....4217
Tools Required....4217
SPN 3662 FMI 5 - Injector 4 close coil ? open circuit....4222
Fault Overview....4222
Lamp Reaction....4222
Associated Faults....4222
Fault Facts....4222
Drive Cycle to Determine Fault Status....4222
Possible Causes....4222
Pin-Point Tests (SPN 3662 FMI 5)....4224
Tools Required....4224
SPN 3663 FMI 5 - Injector 5 close coil ? open circuit....4229
Fault Overview....4229
Lamp Reaction....4229
Associated Faults....4229
Fault Facts....4229
Drive Cycle to Determine Fault Status....4229
Possible Causes....4229
Pin-Point Tests (SPN 3663 FMI 5)....4231
Tools Required....4231
SPN 3664 FMI 5 - Injector 6 close coil ? open circuit....4236
Fault Overview....4236
Lamp Reaction....4236
Associated Faults....4236
Fault Facts....4236
Drive Cycle to Determine Fault Status....4236
Possible Causes....4236
Pin-Point Tests (SPN 3664 FMI 5)....4238
Tools Required....4238
SPN 4257 FMI 7 - Injector Coking Compensation Factor Reached Maximum Authority....4243
Fault Overview....4243
Lamp Reaction....4243
Associated Faults....4243
Fault Facts....4243
Drive Cycle to Determine Fault Status....4243
Possible Causes....4243
SPN 4257 FMI 16 - Multiple Injector High Flow fault....4244
Fault Overview....4245
Lamp Reaction....4245
Associated Faults....4246
Fault Facts....4246
Drive Cycle to Determine Fault Status....4246
Possible Causes....4246
SPN 4257 FMI 18 - Multiple Injector Low Flow fault....4249
Fault Overview....4250
Lamp Reaction....4250
Associated Faults....4251
Fault Facts....4251
Drive Cycle to Determine Fault Status....4251
Possible Causes....4251
IPR (Injection Pressure Regulator)....4254
Overview of IPR Sensor Group....4254
Overview....4254
SPN 679 FMI 3 - IPR Short to PWR....4255
Fault Overview....4255
Lamp Reaction....4255
Associated Faults....4255
Fault Facts....4255
Drive Cycle to Determine Fault Status....4255
Possible Causes....4255
Pin-Point Tests (SPN 679 FMI 3)....4257
Tools Required....4257
SPN 679 FMI 4 - IPR Open or short to GND....4259
Fault Overview....4259
Lamp Reaction....4259
Associated Faults....4259
Fault Facts....4259
Drive Cycle to Determine Fault Status....4259
Possible Causes....4259
Pin-Point Tests (SPN 679 FMI 4)....4261
Tools Required....4261
J1939 Data Link Communications....4265
Overview of J1939 Sensor Group....4265
Overview....4265
SPN 639 FMI 14 - J1939 Data Link Error (ECM unable to transmit)....4266
Fault Overview....4266
Lamp Reaction....4266
Associated Faults....4266
Fault Facts....4266
Drive Cycle to Determine Fault Status....4266
Possible Causes....4266
MAF Sensor (Mass Air Flow)....4268
Overview of MAF Sensor Group....4268
Overview....4268
SPN 132 FMI 0 - Engine Intake Air Mass Flow Rate High....4269
Fault Overview....4269
Lamp Reaction....4270
Associated Faults....4270
Fault Facts....4270
Drive Cycle to Determine Fault Status....4270
Possible Causes....4270
SPN 132 FMI 1 - Engine Intake Air Mass Flow Rate Low....4273
Fault Overview....4273
Lamp Reaction....4273
Associated Faults....4274
Fault Facts....4274
Drive Cycle to Determine Fault Status....4274
Possible Causes....4274
SPN 132 FMI 4 - MAF signal Out of Range LOW....4276
Fault Overview....4276
Lamp Reaction....4276
Associated Faults....4276
Fault Facts....4276
Drive Cycle to Determine Fault Status....4276
Possible Causes....4276
Pin-Point Tests (SPN 132 FMI 4)....4278
Tools Required....4278
SPN 132 FMI 11 - MAF Sensor Calibration ? Insufficient number of data points....4280
Fault Overview....4280
Lamp Reaction....4280
Associated Faults....4280
Fault Facts....4280
Drive Cycle to Determine Fault Status....4280
Possible Causes....4280
SPN 132 FMI 13 - MAF Sensor Calibration Needed....4282
Fault Overview....4282
Lamp Reaction....4282
Associated Faults....4282
Fault Facts....4282
Drive Cycle to Determine Fault Status....4282
Possible Causes....4282
SPN 132 FMI 14 - MAF Sensor Calibration Failed....4284
Fault Overview....4284
Lamp Reaction....4284
Associated Faults....4284
Fault Facts....4284
Drive Cycle to Determine Fault Status....4284
Possible Causes....4284
SPN 132 FMI 31 - MAF Frequency out of range HIGH....4286
Fault Overview....4286
Lamp Reaction....4286
Associated Faults....4286
Fault Facts....4286
Drive Cycle to Determine Fault Status....4286
Possible Causes....4286
Pin-Point Tests (SPN 132 FMI 31)....4288
Tools Required....4288
SPN 172 FMI 2 - IAT Signal Erratic, Intermittent, or Incorrect....4298
Fault Overview....4298
Lamp Reaction....4298
Associated Faults....4298
Fault Facts....4298
Drive Cycle to Determine Fault Status....4298
Possible Causes....4298
Pin-Point Tests (SPN 172 FMI 2)....4300
Tools Required....4300
SPN 172 FMI 3 - IAT Signal Out of Range HIGH....4303
Fault Overview....4303
Lamp Reaction....4303
Associated Faults....4303
Fault Facts....4303
Drive Cycle to Determine Fault Status....4303
Possible Causes....4303
Pin-Point Tests (SPN 172 FMI 3)....4305
Tools Required....4305
SPN 172 FMI 4 - IAT Signal Out of Range LOW....4309
Fault Overview....4309
Lamp Reaction....4309
Associated Faults....4309
Fault Facts....4309
Drive Cycle to Determine Fault Status....4309
Possible Causes....4309
Pin-Point Tests (SPN 172 FMI 4)....4311
Tools Required....4311
NOx (Nitrogen Oxides) Sensor Module....4313
Overview of NOx Sensor Group....4313
Overview....4313
SPN 3216 FMI 4 - NOxIN signal Out of Range LOW....4316
Fault Overview....4316
Lamp Reaction....4316
Associated Faults....4316
Fault Facts....4316
Drive Cycle to Determine Fault Status....4316
Possible Causes....4316
SPN 3216 FMI 10 - NOxIN signal abnormal rate of change....4318
Fault Overview....4318
Lamp Reaction....4318
Associated Faults....4318
Fault Facts....4318
Drive Cycle to Determine Fault Status....4318
Possible Causes....4318
SPN 3216 FMI 13 - NOx IN Out of Calibration....4320
Fault Overview....4320
Lamp Reaction....4320
Associated Faults....4320
Fault Facts....4320
Drive Cycle....4320
Possible Causes....4320
SPN 3216 FMI 19 - NOx IN not detected on J1939....4323
Fault Overview....4323
Lamp Reaction....4323
Associated Faults....4323
Fault Facts....4323
Drive Cycle to Determine Fault Status....4323
Possible Causes....4323
Pin-Point Tests (SPN 3216 FMI 19)....4326
Tools Required....4326
SPN 3216 FMI 20 - NOxIN signal drifted HIGH....4335
Fault Overview....4335
Lamp Reaction....4335
Associated Faults....4335
Drive Cycle to Determine Fault Status....4335
Possible Causes....4335
SPN 3216 FMI 21 - NOxIN signal drifted LOW....4337
Fault Overview....4337
Lamp Reaction....4337
Associated Faults....4337
Fault Facts....4337
Drive Cycle to Determine Fault Status....4337
Possible Causes....4337
SPN 3218 FMI 2 - NOxIN power supply signal erratic, intermittent or incorrect....4339
Fault Overview....4339
Lamp Reaction....4339
Associated Faults....4339
Drive Cycle to Determine Fault Status....4339
Pin-Point Tests (SPN 3218 FMI 2)....4341
Tools Required....4341
SPN 3226 FMI 2 - NOx OUT Signal Erratic, Intermittent, or Incorrect....4345
Fault Overview....4345
Lamp Reaction....4345
Associated Faults....4345
Fault Facts....4345
Drive Cycle to Determine Fault Status....4345
Possible Causes....4345
Pin-Point Tests SPN 3226 FMI 2....4349
Tools Required....4349
SPN 3226 FMI 4 - NOxOUT signal Out of Range LOW....4352
Fault Overview....4352
Lamp Reaction....4352
Associated Faults....4352
Fault Facts....4352
Drive Cycle to Determine Fault Status....4352
Possible Causes....4352
SPN 3226 FMI 10 - NOx OUT Signal Abnormal Rate of Change....4354
Fault Overview....4354
Lamp Reaction....4354
Associated Faults....4354
Fault Facts....4354
Drive Cycle to Determine Fault Status....4354
Possible Causes....4354
SPN 3226 FMI 13 - NOxOUT Out of Calibration....4356
Fault Overview....4356
Lamp Reaction....4356
Associated Faults....4356
Fault Facts....4356
Drive Cycle to Determine Fault Status....4356
Possible Causes....4356
SPN 3226 FMI 19 - NOxOUT not detected on J1939....4358
Fault Overview....4358
Lamp Reaction....4358
Associated Faults....4358
Fault Facts....4358
Drive Cycle to Determine Fault Status....4358
Possible Causes....4358
Pin-Point Tests (SPN 3226 FMI 19)....4360
Tools Required....4360
SPN 3226 FMI 20 - NOxOUT signal drifted HIGH....4368
Fault Overview....4368
Lamp Reaction....4368
Associated Faults....4368
Fault Facts....4368
Drive Cycle to Determine Fault Status....4368
Possible Causes....4368
SPN 3226 FMI 21 - NOxOUT signal drifted LOW....4370
Fault Overview....4370
Lamp Reaction....4370
Associated Faults....4370
Fault Facts....4370
Drive Cycle to Determine Fault Status....4370
Possible Causes....4370
SPN 3228 FMI 2 - NOxOUT power supply signal erratic, intermittent or incorrect....4372
Fault Overview....4372
Lamp Reaction....4372
Associated Faults....4372
Fault Facts....4372
Drive Cycle to Determine Fault Status....4372
Possible Causes....4372
Pin-Point Tests (SPN 3228 FMI 2)....4376
Tools Required....4376
SPN 5024 FMI 10 - NOxIN Sensor Heater abnormal rate of change....4379
Fault Overview....4379
Lamp Reaction....4379
Associated Faults....4379
Fault Facts....4379
Drive Cycle to Determine Fault Status....4379
Possible Causes....4379
Pin-Point Tests (SPN 5024 FMI 10)....4381
Tools Required....4381
SPN 5031 FMI 10 - NOxOUT Sensor Heater not reading correctly....4384
Fault Overview....4384
Lamp Reaction....4384
Associated Faults....4384
Fault Facts....4384
Drive Cycle to Determine Fault Status....4385
Possible Causes....4385
Pin-Point Tests (SPN 5031 FMI 10)....4387
Tools Required....4387
RAPP (Remote APP) Sensor....4390
Overview of RAPP Sensor Group....4390
Overview....4390
SPN 974 FMI 3 - Remote APP signal Out of Range HIGH....4391
Fault Overview....4391
Lamp Reaction....4391
Associated Faults....4391
Fault Facts....4391
Drive Cycle to Determine Fault Status....4391
Possible Causes....4391
Pin-Point Tests (SPN 974 FMI 3)....4392
Tools Required....4392
SCR (Temperature Sensor Module)....4393
Overview of SCR Sensor Group....4393
Overview....4393
SPN 3061 FMI 31 - CSER Exhaust warm up time fault....4395
Fault Overview....4395
Lamp Reaction....4395
Associated Faults....4395
Fault Facts....4395
Drive Cycle to Determine Fault Status....4395
Possible Causes....4395
SPN 4364 FMI 18- Low NOx Conversion Detected....4399
Fault Overview....4400
Lamp Reaction....4400
Associated Faults....4400
Fault Facts....4400
Drive Cycle to Determine Fault Status....4400
Possible Causes....4400
SPN 4792 FMI 7 - SCR Catalyst System - Mechanical system not responding or out of adjustment....4405
Fault Overview....4405
Lamp Reaction....4405
Associated Faults....4405
Fault Facts....4405
Drive Cycle to Determine Fault Status....4405
Possible Causes....4405
SPN 4792 FMI 14 - SCR Temperature Module (Incorrect Part)....4407
Fault Overview....4407
Lamp Reaction....4407
Associated Faults....4407
Fault Facts....4407
Drive Cycle to Determine Fault Status....4407
Possible Causes....4407
SPN 4794 FMI 31 - SCR Catalyst System Missing....4409
Fault Overview....4409
Lamp Reaction....4409
Associated Faults....4409
Fault Facts....4409
Drive Cycle to Determine Fault Status....4410
Possible Causes....4410
SPN 5743 FMI 3 - SCR Thermocouple Controller Out of Range HIGH....4412
Fault Overview....4412
Lamp Reaction....4412
Associated Faults....4412
Fault Facts....4412
Drive Cycle to Determine Fault Status....4412
Possible Causes....4412
Pin-Point Tests (SPN 5743 FMI 3)....4414
Tools Required....4414
SPN 5743 FMI 4 - SCR Thermocouple Controller Out of Range LOW....4416
Fault Overview....4416
Lamp Reaction....4416
Associated Faults....4416
Fault Facts....4416
Drive Cycle to Determine Fault Status....4416
Possible Causes....4416
Pin-Point Tests (SPN 5743 FMI 4)....4418
Tools Required....4418
SPN 5743 FMI 11 - SCR Thermocouple Controller signal erratic, intermittent, or incorrect....4421
Fault Overview....4421
Lamp Reaction....4421
Associated Faults....4421
Fault Facts....4421
Drive Cycle to Determine Fault Status....4421
Possible Causes....4421
Pin-Point Tests (SPN 5743 FMI 11)....4423
Selective Catalyst Reduction (SCR) Temperature Sensor Module Circuit....4423
Tools Required....4423
SPN 5743 FMI 16 - SCR Thermocouple Controller above Maximum Temperature....4427
Fault Overview....4427
Lamp Reaction....4427
Associated Faults....4427
Fault Facts....4427
Drive Cycle to Determine Fault Status....4427
Possible Causes....4427
SPN 5743 FMI 19 - SCR Temperature module not detect J1939....4429
Fault Overview....4429
Lamp Reaction....4429
Associated Faults....4429
Fault Facts....4429
Drive Cycle to Determine Fault Status....4429
Possible Causes....4429
Pin-Point Tests (SPN 5743 FMI 19)....4431
Tools Required....4431
SCRIT (Selective Catalyst Reduction Intake Temperature) Sensor....4440
Overview of SCRIT Sensor Group....4440
Overview....4440
SPN 4360 FMI 0 - SCRIT above Critical Temperature....4441
Fault Overview....4441
Lamp Reaction....4441
Associated Faults....4441
Fault Facts....4441
Drive Cycle to Determine Fault Status....4441
Possible Causes....4441
SPN 4360 FMI 2- SCRIT signal erratic, intermittent or incorrect....4444
Fault Overview....4444
Lamp Reaction....4444
Associated Faults....4444
Fault Facts....4444
Drive Cycle to Determine Fault Status....4445
Possible Causes....4445
SPN 4360 FMI 3 - SCRIT Signal Out of Range HIGH....4447
Fault Overview....4447
Lamp Reaction....4447
Associated Faults....4447
Fault Facts....4447
Drive Cycle to Determine Fault Status....4447
Possible Causes....4447
SPN 4360 FMI 4 - SCRIT Signal Out of Range LOW....4449
Fault Overview....4449
Lamp Reaction....4449
Associated Faults....4449
Fault Facts....4449
Drive Cycle to Determine Fault Status....4449
Possible Causes....4449
SPN 4360 FMI 16 - SCRIT above Maximum Temperature....4451
Fault Overview....4451
Lamp Reaction....4451
Associated Faults....4451
Fault Fact....4451
Drive Cycle to Determine Fault Status....4451
Possible Causes....4451
SCROT (Selective Catalyst Reduction Outlet Temperature) Sensor....4454
Overview of SCROT Sensor Group....4454
Overview....4454
SPN 4363 FMI 0 - SCROT above Critical Temperature....4455
Fault Overview....4455
Lamp Reaction....4455
Associated Faults....4455
Fault Facts....4455
Drive Cycle to Determine Fault Status....4455
Possible Causes....4455
SPN 4363 FMI 2 - SCROT signal erratic, intermittent or incorrect....4458
Fault Overview....4458
Lamp Reaction....4458
Associated Faults....4458
Fault Facts....4458
Drive Cycle to Determine Fault Status....4458
Possible Causes....4458
SPN 4363 FMI 3 - SCROT signal Out of Range HIGH....4460
Fault Overview....4460
Lamp Reaction....4460
Associated Faults....4460
Fault Facts....4460
Drive Cycle to Determine Fault Status....4460
Possible Causes....4460
SPN 4363 FMI 4 - SCROT signal Out of Range LOW....4462
Fault Overview....4462
Lamp Reaction....4462
Associated Faults....4462
Fault Facts....4462
Drive Cycle to Determine Fault Status....4462
Possible Causes....4462
TC2CIT (Turbocharger 2 Compressor Intake Temperature)....4464
Overview of TC2CIT Sensor Group....4464
Overview....4464
SPN 1173 FMI 2 - TC2CIT signal erratic, intermittent, or incorrect....4465
Fault Overview....4465
Lamp Reaction....4465
Associated Faults....4465
Fault Facts....4465
Drive Cycle to Determine Fault Status....4465
Possible Causes....4465
Pin-Point Tests (SPN 1173 FMI 2)....4467
Tools Required....4467
SPN 1173 FMI 3 - TC2CIT Signal Out of Range HIGH....4471
Fault Overview....4471
Lamp Reaction....4471
Associated Faults....4471
Fault Facts....4471
Drive Cycle to Determine Fault Status....4471
Possible Causes....4471
Pin-Point Tests (SPN 1173 FMI 3)....4473
Tools Required....4473
SPN 1173 FMI 4 - TC2CIT Signal Out of Range LOW....4477
Fault Overview....4477
Lamp Reaction....4477
Associated Faults....4477
Fault Facts....4477
Drive Cycle to Determine Fault Status....4477
Possible Causes....4477
Pin-Point Tests (SPN 1173 FMI 4)....4479
Tools Required....4479
SPN 1173 FMI 16 - TC2CIT signal above desired (Low Pressure CAC Interstage under cooling)....4481
Fault Overview....4481
Lamp Reaction....4481
Associated Faults....4482
Fault Facts....4482
Drive Cycle to Determine Fault Status....4482
Possible Causes....4482
TC2WG (Turbocharger 2 Wastegate Position)....4483
Overview of TC2WG Group....4483
Overview....4483
SPN 1189 FMI 3 - TC2WC short to PWR....4484
Fault Overview....4484
Lamp Reaction....4484
Associated Faults....4484
Fault Facts....4484
Drive Cycle to Determine Fault Status....4484
Possible Causes....4484
Pin-Point Tests SPN 1189 FMI 3....4486
Tools Required....4486
SPN 1189 FMI 4 - TC2WC Open or short to GND....4488
Fault Overview....4488
Lamp Reaction....4488
Associated Faults....4488
Fault Facts....4488
Drive Cycle to Determine Fault Status....4488
Possible Causes....4488
Pin-Point Tests (SPN 1189 FMI 4)....4490
Tools Required....4490
TOSS (Transmission Output Shaft Speed) Sensor....4494
Overview of TOSS Sensor Group....4494
Overview....4494
SPN 191 FMI 3 - TOSS/VSS signal out of range HIGH....4496
Fault Overview....4496
Lamp Reaction....4496
Associated Faults....4496
Fault Facts....4496
Drive Cycle to Determine Fault Status....4496
Possible Causes....4496
Pin-Point Tests (SPN 191 FMI 3)....4498
Tools Required....4498
SPN 191 FMI 4 - TOSS/VSS signal out of range LOW....4500
Fault Overview....4500
Lamp Reaction....4500
Associated Faults....4500
Fault Facts....4500
Drive Cycle to Determine Fault Status....4500
Possible Causes....4500
Pin-Point Tests (SPN 191 FMI 4)....4502
Tools Required....4502
SPN 191 FMI 5 - TOSS/VSS Open Circuit fault....4504
Fault Overview....4504
Lamp Reaction....4504
Associated Faults....4504
Fault Facts....4504
Drive Cycle to Determine Fault Status....4504
Possible Causes....4504
Pin-Point Tests (SPN 191 FMI 5)....4506
Tools Required....4506
SPN 191 FMI 14 - TOSS/VSS Error invalid signal....4509
Fault Overview....4509
Lamp Reaction....4509
Associated Faults....4509
Fault Facts....4509
Drive Cycle to Determine Fault Status....4509
Possible Causes....4509
VREF (Voltage Reference)....4511
Overview of VREF Sensor Group....4511
Overview....4511
SPN 3509 FMI 3 - VREF 1 voltage above maximum....4512
Fault Overview....4512
Lamp Reaction....4512
Associated Faults....4512
Fault Facts....4512
Drive Cycle to Determine Fault Status....4512
Possible Causes....4512
Pin-Point Tests (SPN 3509 FMI 3)....4514
Tools Required....4514
SPN 3509 FMI 4 - VREF 1 voltage below minimum....4520
Fault Overview....4520
Lamp Reaction....4520
Associated Faults....4520
Fault Facts....4520
Drive Cycle to Determine Fault Status....4520
Possible Causes....4520
Pin-Point Tests (SPN 3509 FMI 3)....4520
Tools Required....4520
SPN 3510 FMI 3 - VREF 2 voltage above maximum....4533
Fault Overview....4533
Lamp Reaction....4533
Associated Faults....4533
Fault Facts....4533
Drive Cycle to Determine Fault Status....4533
Possible Causes....4533
Pin-Point Tests (SPN 3510 FMI 3)....4535
Tools Required....4535
SPN 3510 FMI 4 - VREF 2 voltage below minimum....4538
Fault Overview....4538
Lamp Reaction....4538
Associated Faults....4538
Fault Facts....4538
Drive Cycle to Determine Fault Status....4538
Possible Causes....4538
Pin-Point Tests (SPN 3510 FMI 4)....4540
Tools Required....4540
SPN 3511 FMI 3 - VREF 3 voltage above maximum....4545
Fault Overview....4545
Lamp Reaction....4545
Associated Faults....4545
Fault Facts....4545
Drive Cycle to Determine Fault Status....4545
Possible Causes....4545
Pin-Point Tests (SPN 3511 FMI 3)....4547
Tools Required....4547
SPN 3511 FMI 4 - VREF 3 voltage below minimum....4552
Fault Overview....4552
Lamp Reaction....4552
Associated Faults....4552
Fault Facts....4552
Drive Cycle to Determine Fault Status....4552
Possible Causes....4552
Pin-Point Tests (SPN 3511 FMI 4)....4554
Tools Required....4554
WIF Sensor (Water In Fuel)....4560
Overview of WIF Sensor Group....4560
Overview....4560
SPN 4192 FMI 3 - WIF signal Out of Range HIGH....4561
Fault Overview....4561
Lamp Reaction....4561
Associated Faults....4561
Fault Facts....4561
Drive Cycle to Determine Fault Status....4561
Possible Causes....4561
Pin-Point Tests SPN 4192 FMI 3....4563
Tools Required....4563
SPN 4192 FMI 4 - WIF signal Out of Range LOW....4565
Fault Overview....4565
Lamp Reaction....4565
Associated Faults....4565
Fault Facts....4565
Drive Cycle to Determine Fault Status....4565
Possible Causes....4565
Pin-Point Tests SPN 4192 FMI 4....4567
Tools Required....4567
SPN 4192 FMI 5 - WIF signal Open or Short to PWR....4569
Fault Overview....4569
Lamp Reaction....4569
Associated Faults....4569
Fault Facts....4569
Drive Cycle to Determine Fault Status....4569
Possible Causes....4569
Pin-Point Tests SPN 4192 FMI 5....4571
Tools Required....4571
SPN 4192 FMI 31 - Water in Fuel Detected....4575
Fault Overview....4575
Lamp Reaction....4575
Associated Faults....4575
Fault Facts....4575
Drive Cycle to Determine Fault Status....4575
Possible Causes....4575
Table of Contents....4577
How To Use This Section....4581
ServiceMaxx? Software Procedures....4582
ServiceMaxx? Connection and Data Recording....4582
Overview....4582
Engine Auto-Detection....4582
Connection (Sniffer)....4582
Tools Required....4582
Equipment Condition....4582
Test Setup....4583
Test Procedure....4584
Snapshot Recording Procedure:....4584
Snapshot Playback Procedure....4585
Diagnostic Trouble Code Overview....4587
DTC Type:....4587
Pending DTC....4587
Active DTC....4587
Healing DTC....4587
Previously Active DTC....4587
DTC Count....4587
Freeze Frame....4587
Check for DTCs....4588
Procedure:....4588
Session Files....4589
Overview....4589
Hot Run Sensor Comparison Test....4590
Purpose....4590
Tools Required....4590
Obtain Vehicle Health Report....4593
Overview....4593
Tools Required....4593
Equipment Condition....4593
Test Setup....4593
Test Procedure....4593
Expected Outcome....4593
Follow-On Procedure....4593
Programmable Features....4594
Overview....4594
Tool Required....4594
Equipment Condition....4594
Test Setup....4595
Test Procedure....4596
Expected Outcome....4598
Follow-On Procedure....4598
Record Snapshot of KOEO Data....4599
Overview....4599
Tools Required....4599
Equipment Condition....4599
Test Setup....4599
Test Procedure....4599
Expected Outcome....4599
Follow-On Procedure....4599
Injector Coil End of Motion (CEOM) Reset Procedure....4600
Overview....4600
Tools Required....4600
Equipment Condition....4600
Test Setup....4601
Test Procedure....4602
Fuel Pressure Adaptation Reset....4603
Overview....4603
Tools Required....4603
Equipment Condition....4603
Test Setup....4604
Test Procedure....4604
Follow-On Procedure....4605
KOEO DOC / DPF Replacement / Reset Procedure....4606
Overview....4606
Tools Required....4607
Equipment Condition....4607
Test Setup....4607
Test Procedure....4607
Intermittent or Inactive Fault Diagnostic Procedure....4609
Overview....4609
Tools Required....4609
Equipment Condition....4609
Test Setup....4609
Test Procedure....4609
Expected Outcome....4609
Follow-On Procedure....4609
Connecting EST with ServiceMaxx? Software to Engine....4610
Interface Device Selection....4610
Connecting ServiceMaxx? Software....4613
Pinpoint Diagnostic Graphic Legend....4614
Service Bay Tests....4622
Engine Off Tests....4622
KOEO Standard Test....4622
Overview....4622
Tools Required....4622
Equipment Condition....4622
Test Setup....4623
Test Procedure....4624
Expected Outcome....4625
Follow-On Procedure....4625
KOEO Low to High Idle Test....4626
Overview....4626
Tools Required....4626
Equipment Condition....4626
Test Setup....4626
Test Procedure....4627
Expected Outcome....4629
Follow-On Procedure....4629
KOEO Output State High or Low....4631
Overview....4631
Actuators that cycle during this test:....4631
Tools Required....4631
Equipment Condition....4631
Test Setup....4631
Test Procedure....4631
Expected Outcome....4632
Follow-On Procedure....4632
Continuous Monitor....4633
Overview....4633
Position Sensor Voltages are Monitored:....4634
Pressure Sensor Voltages are Monitored:....4634
Temperature Sensor Voltages are Monitored:....4634
Other Voltage Signals Monitored:....4634
Tools Required....4634
Equipment Condition....4634
Test Setup....4635
Test Procedure....4635
Follow-on Procedure....4636
KOEO DEF Tank Heater Test....4637
Overview....4637
Tools Required....4637
Equipment Conditions....4637
Test Setup....4638
Test Procedure....4639
Expected Outcome....4639
Follow-On Procedure....4639
KOEO Injector Test....4640
Overview....4640
Tools Required....4640
Equipment Condition....4640
Test Setup....4640
Test Procedure....4640
Expected Outcome....4641
Follow-on Procedure....4641
KOEO DCU Actuator Test ? Actuator Output High and Low Diagnostics....4642
Overview....4642
Tools Required....4642
Test Setup....4643
Test Procedure....4643
Expected Outcome....4644
Follow-On Procedure....4644
KOEO DEF System Leak Test....4645
Overview....4645
Tools Required....4645
Equipment Condition....4645
Test Setup....4645
Test Procedure....4645
Expected Outcome....4646
Follow-On Procedure....4646
KOEO DEF Line Heater Test....4647
Overview....4647
Tools Required....4647
Equipment Condition....4647
Test Setup....4647
Test Procedure....4647
Expected Outcome....4648
Follow-On Procedure....4648
KOEO DEF Reverting Control Valve Test....4649
Overview....4649
Tools Required....4649
Test Setup....4649
Test Procedure....4650
Expected Outcome....4650
Follow-On Procedure....4650
KOEO DEF Supply Pump Override Test....4651
Overview....4651
Tools Required....4651
Equipment Conditions....4651
Test Setup....4651
Test Procedure....4651
Expected Outcome....4652
Follow-On Procedure....4652
KOEO Relative Compression Test....4653
Overview....4653
Tools Required....4653
Test Setup....4653
Test Procedure....4654
Expected Outcome....4655
Follow-On Procedure....4655
KOEO SCR Faults Reset Request Procedure....4656
Overview....4656
Tools Required....4656
Equipment Condition....4656
Test Setup....4656
Test Procedure....4656
Expected Outcome....4657
Follow-On Procedure....4657
KOEO Engine Cranking Test....4658
Overview....4658
Tools Required....4658
Equipment Condition....4658
Test Setup....4658
Procedure....4659
Expected Outcome....4660
Follow-on Procedure....4660
Engine Running Tests....4661
KOER Air Management Test....4661
Overview....4661
Tools Required....4661
Equipment Conditions....4661
Test Setup....4662
Test Procedure....4662
Expected Outcome....4662
Follow-On Procedure....4662
Air Management System Graph (GOOD)....4663
Overview....4663
Tools Required....4663
Equipment Condition....4663
Test Setup....4663
Test Procedure....4664
Expected Outcome....4664
Follow-On Procedure....4664
Air Management System Graph (BAD) ....4665
Overview....4665
Tools Required....4665
Equipment Condition....4665
Test Setup....4665
Test Procedure....4666
Expected Outcome....4666
Follow-On Procedure....4666
KOER Standard Test....4667
Overview....4667
Tools Required....4667
Equipment Conditions....4667
Test Setup....4668
Test Procedure....4669
Expected Outcome....4669
Follow-On Procedure....4669
KOER Cylinder Cutout Test....4670
Overview....4670
Tools Required....4670
Equipment Condition....4670
Test Setup....4670
Test Procedure....4671
Expected Outcome....4672
Follow-on Procedure....4672
KOER DSI System Test....4673
Overview....4673
Tools Required....4673
Equipment Conditions....4674
Test Setup....4674
Test Procedure....4674
Expected Outcome....4675
Follow-On Procedure....4675
KOER DSI Deaeration Procedure....4676
Overview....4676
Tools Required....4676
Equipment Condition....4676
Test Setup....4677
Test Procedure....4678
Expected Outcome....4678
Follow-On Procedure....4678
KOER Aftertreatment DPF Regeneration Procedure....4679
Overview....4679
Tools Required....4679
Equipment Condition....4679
Test Setup....4680
Test Procedure....4681
Expected Outcome....4682
Follow-On Procedure....4682
Connect Cylinder Performance Analyzer (CPA) Tool....4683
Overview....4683
Tools Required....4683
Equipment Condition....4683
Test Setup....4684
Test Procedure....4685
Expected Outcome....4686
Follow-on Procedure....4686
Cylinder Performance Analyzer (CPA) Cold Idle Test....4687
Overview....4687
Tools Required....4687
Equipment Condition....4687
Test Setup....4687
Test Procedure....4690
Expected Outcome....4691
Follow-on Procedure....4691
Cylinder Performance Analyzer (CPA) Signal Check....4692
Overview....4692
Tools Required....4692
Equipment Condition....4692
Test Setup....4692
Test Procedure....4694
Expected Outcome....4697
Follow-On Procedure....4697
Cylinder Performance Analyzer (CPA) Hot Idle Test....4698
Overview....4698
Tools Required....4698
Equipment Condition....4698
Test Setup....4698
Test Procedure....4701
Expected Outcome....4702
Follow-On Procedure....4702
Cylinder Performance Analyzer (CPA) Road Test....4703
Overview....4703
Tools Required....4703
Equipment Condition....4703
Test Setup....4703
Test Procedure....4706
Expected Outcome....4707
Follow-On Procedure....4707
Cylinder Performance Analyzer (CPA) Advanced Testing....4708
Overview....4708
Tools Required....4708
Equipment Condition....4708
Test Setup....4708
Test Procedure....4710
Expected Outcome....4712
Follow-on Procedure....4712
Cylinder Performance Analyzer (CPA) ? High-Pressure Oil Pump (HPOP) Test....4713
Overview....4713
Tools Required....4713
Equipment Condition....4713
Test Setup....4713
Test Procedure....4715
Expected Outcome....4716
Follow-on Procedure....4716
Record Snapshot of Engine Running Data....4717
Overview....4717
Tools Required....4717
Equipment Condition....4717
Test Setup....4717
Test Procedure....4718
Expected Outcome....4720
Follow-On Procedure....4720
Road Test....4721
0 to 60 MPH Test....4722
Overview....4722
Tools Required....4722
Equipment Condition....4722
Test Setup....4722
Test Procedure....4722
Expected Outcome....4725
Follow-on Procedure....4725
0 to 60 MPH ICP and ICPD Graph ....4726
Overview....4726
Tools Required....4726
Equipment Condition....4726
Test Setup....4726
Test Procedure....4727
Expected Outcome....4727
Follow-On Procedure....4727
0 to 60 MPH RPM, Load, IMP, EBP, and APP1 Graph....4728
Overview....4728
Tools Required....4728
Equipment Condition....4728
Test Setup....4728
Test Procedure....4729
Expected Outcome....4729
Follow-On Procedure....4730
Normal Exhaust Gas Temperature Graph....4731
Overview....4731
Tools Required....4731
Equipment Condition....4731
Test Setup....4731
Test Procedure....4732
Expected Outcome....4732
Follow-On Procedure....4733
Erratic Exhaust Gas Temperatures Graph....4734
Overview....4734
Tools Required....4734
Equipment Condition....4734
Test Setup....4734
Test Procedure....4735
Expected Outcome ....4735
Follow-On Procedure....4736
Low Exhaust Gas Temperatures Graph....4737
Overview....4737
Tools Required....4737
Equipment Condition....4737
Test Setup....4737
Test Procedure....4738
Expected Outcome....4738
Follow-On Procedure....4739
Air Control Valve (ACV) Test....4740
Exhaust Back Pressure Valve (EBPV) Test....4740
Overview....4740
Tools Required....4740
Equipment Condition....4740
Test Setup....4740
Test Procedure....4740
Expected Outcome....4741
Follow-on Procedure....4741
Boost Control System Test....4742
Overview....4742
Tools Required....4742
Equipment Condition....4742
Test Setup....4742
Test Procedure....4743
Expected Outcome....4744
Follow-On Procedure....4744
Turbocharger 2 Wastegate Position (TC2WG) Operational Test....4745
Overview....4745
Tools Required....4745
Equipment Condition....4745
Test Setup....4745
Test Procedure....4747
Expected Outcome....4747
Follow-On Procedure....4748
Turbocharger 2 Wastegate Position (TC2WG) Solenoid Test....4749
Overview....4749
Tools Required....4749
Equipment Condition....4749
Test Setup....4749
Test Procedure....4749
Expected Outcome....4749
Follow-On Procedure....4749
Turbocharger 2 Wastegate Position (TC2WG) Isolated Actuator Test....4750
Overview....4750
Tools Required....4750
Equipment Condition....4750
Test Setup....4751
Test Procedure....4752
Expected Outcome....4753
Follow-On Procedure....4753
KOER MAF Sensor Calibrations....4754
Overview....4754
Tools Required....4754
Equipment Condition....4754
MAF Calibration Pre-Checks....4754
Test Setup....4755
Test Procedure....4756
Expected Outcome....4756
Follow-On Procedure....4756
Exhaust Gas Recirculation (EGR) Valve Operational Test....4757
Overview....4757
Tool Required....4757
Equipment Condition....4757
Test Setup....4757
Test Procedure....4757
Expected Outcome....4758
Follow-On Maintenance....4758
Low-pressure Fuel System Tests....4759
Fuel Delivery Pressure (FDP) Test....4759
Overview....4759
Tools Required....4759
Equipment Condition....4759
Test Setup....4760
Test Procedure....4761
Expected Outcome....4761
Follow-On Procedure....4761
Fuel Pump Voltage Test....4762
Overview....4762
Tools Required....4762
Equipment Condition....4762
Test Setup....4762
Test Procedure....4763
Expected Outcome....4764
Follow-On Procedure....4764
Clean Fuel Source Test....4765
Overview....4765
Tools Required....4765
Equipment Condition....4765
Test Setup....4765
Test Procedure....4767
Expected Outcome....4767
Follow-on Procedure....4768
Intake Air Heater (IAH) Tests....4769
Intake Air Heater (IAH) System Test....4769
Overview....4769
Tools Required....4769
Equipment Condition....4769
Test Setup....4769
Test Procedure....4770
Expected Outcome....4770
Follow-on Procedure....4770
Intake Air Heater (IAH) Current Draw Test....4771
Overview....4771
Tools Required....4771
Equipment Condition....4771
Test Setup....4771
Test Procedure....4772
Expected Outcome....4773
Intake Air Heater (IAH) Relay Test....4774
Overview....4774
Tools Required....4774
Equipment Condition....4774
Test Setup....4774
Test Procedure....4775
Expected Outcome....4776
Follow-On Procedure....4776
High-Pressure Charge Air Cooler (HPCAC) Pressure Test....4777
Overview....4777
Tools Required....4777
Equipment Condition....4777
Test Setup....4778
Test Procedure....4779
Expected Outcome....4783
Follow-On Procedure....4783
Interstage Cooler (ISC) Pressure Test....4784
Overview....4784
Tools Required....4784
Equipment Condition....4784
Test Setup....4785
Test Procedure....4787
Expected Outcome....4787
Follow-On Procedure....4787
Crankcase Pressure Test....4788
Overview....4788
Tools Required....4788
Equipment Condition....4788
Test Setup....4788
Test Procedure....4791
Expected Outcome....4792
Follow-on Procedure....4792
General Test Procedures....4793
Coolant Heater Assembly Test....4793
Overview....4793
Tools Required....4793
Equipment Condition....4793
Test Setup....4793
Test Procedure....4793
Expected Outcome....4794
Follow-On Procedure....4794
Oil Pan Heater Test....4795
Overview....4795
Tools Required....4795
Equipment Condition....4795
Test Setup....4795
Test Procedure....4795
Expected Outcome....4796
Follow-On Procedure....4796
Coolant Test Procedures....4797
Deaeration Tank Cap Test....4797
Overview....4797
Tools Required....4797
Equipment Condition....4798
Test Setup....4799
Test Procedure....4799
Expected Outcome....4799
Follow-on Procedure....4799
Cooling System Pressure Test....4800
Overview....4800
Tools Required....4800
Equipment Condition....4800
Test Setup....4801
Test Procedure....4802
Expected Outcome....4803
Follow-on Procedure....4803
Coolant Over-Flow / Over-Temperature Test....4804
Overview....4804
Tools Required....4804
Equipment Condition....4804
Test Setup....4804
Test Procedure....4804
Expected Outcome....4804
Follow-On Procedure....4804
Thermostat Operational Test....4805
Overview....4805
Tools Required....4805
Equipment Condition....4805
Test Setup....4805
Test Procedure....4805
Expected Outcome....4806
Follow-On Procedure....4806
Engine Cooling Fan Test....4808
Overview....4808
Tools Required....4808
Equipment Condition....4808
Test Setup....4808
Test Procedure....4808
Expected outcome....4809
Air Compressor Coolant Leak Test....4810
Overview....4810
Tools Required....4810
Equipment Condition....4810
Test Setup....4810
Test Procedure....4811
Expected Outcome....4811
Follow-on Procedure....4811
Air Compressor Overflow Test....4812
Overview....4812
Tools Required....4812
Equipment Condition....4812
Test Setup....4812
Test Procedure....4812
Expected Outcome....4812
Follow-on Procedure....4812
Combustion in Cooling System Test....4813
Overview....4813
Tools Required....4813
Equipment Condition....4813
Test set-up....4813
Test Procedure....4814
Expected Outcome....4814
Follow-On Procedure....4814
On-Engine EGR Cooler Leak Test....4815
Overview....4815
Tools Required....4815
Equipment Condition....4815
Test Setup....4815
Test Procedure....4817
Expected Outcome....4817
Follow-On Procedure....4817
Instrument Cluster Temperature Gauge Validation Test....4818
Overview....4818
Tools Required....4818
Equipment Condition....4818
Test Setup....4818
Test Procedure....4818
Expected Outcome....4819
Follow-On Procedure....4819
Engine Oil Tests....4820
Oil Cooler Pressure Test....4820
Overview....4820
Tools Required....4820
Equipment Condition....4820
Test Setup....4820
Test Procedure....4821
Expected Outcome....4822
Follow-on Procedure....4822
Oil Pressure Verification Test....4823
Overview....4823
Tools Required....4823
Equipment Condition....4823
Test Setup....4823
Test Procedure....4824
Expected Outcome....4824
Follow-on Procedure....4825
Instrument Cluster Engine Oil Pressure Gauge Validation Test....4826
Overview....4826
Tools Required....4826
Equipment Condition....4826
Test Setup....4827
Test Procedure....4827
Expected Outcome....4828
Follow-On Procedure....4828
Oil Breather Separator Test....4829
Overview....4829
Tools Required....4829
Equipment Condition....4829
Test Setup....4829
Test Procedure....4830
Expected Outcome....4830
Follow-on Procedure....4830
Oil Aeration Test....4831
Engine Brake....4832
Engine Brake Operational Check....4832
Engine Brake ECM Input Check....4833
Engine Brake Slave Piston Binding Test....4834
Engine System Inspections....4835
Fuel System Inspection....4835
Overview....4835
Tools Required....4835
Equipment Condition....4835
Inspection Procedure....4835
Expected Outcome....4835
Fuel Quality Inspection....4836
Overview....4836
Tools Required....4836
Inspection Procedure....4837
Expected Outcome....4837
Fuel Level Inspection....4838
Overview....4838
Tools Required....4838
Equipment Condition....4838
Inspection Procedure....4838
Expected Outcome....4838
Engine Oil and Quality Check....4839
Overview....4839
Tools Required....4839
Equipment Condition....4839
Inspection Procedure....4840
Expected Outcome....4840
Coolant Level Inspection....4841
Overview....4841
Tools Required....4841
Equipment Condition....4841
Inspection Procedure....4841
Expected Outcome....4841
Coolant Quality Inspection....4842
Overview....4842
Tools Required....4842
Equipment Condition....4842
Inspection Procedure....4842
Expected Outcome....4842
Coolant in Exhaust Inspection....4843
Overview....4843
Tools Required....4843
Inspection Procedure....4843
Expected Outcome....4843
Interstage Cooler (ISC) Coolant Leak Inspection....4844
Overview....4844
Tools Required....4844
Equipment Condition....4844
Inspection Procedure....4845
Expected Outcome....4845
Coolant Leak Visual Inspection ....4846
Overview....4846
Tools Required....4846
Equipment Condition....4846
Inspection Procedure....4846
Expected Outcome....4846
Coolant To Intake Inspection....4847
Overview....4847
Tools Required....4847
Equipment Condition....4847
Inspection Procedure....4848
Expected Outcome....4848
Charge Air Cooler Inspection....4849
Overview....4849
Tools Required....4849
Equipment Condition....4849
Inspection Procedure....4849
Expected Outcome....4850
Intake Air Inspection....4851
Overview....4851
Tools Required....4851
Equipment Condition....4851
Inspection Procedure....4851
Expected Outcome....4851
Front Gear Train Coolant Leak Inspection....4852
Overview....4852
Tools Required....4852
Equipment Condition....4852
Inspection Procedure....4852
Expected Outcome....4853
Exhaust and Aftertreatment System Inspection....4854
Overview....4854
Tools Required....4854
Equipment Condition....4854
Inspection Procedure....4854
Expected Outcome....4855
Diesel Particulate Filter (DPF) Inspection....4856
Overview....4856
Tools Required....4856
Equipment Condition....4856
Inspection Procedure....4857
Expected Outcome....4858
Diesel Oxidation Catalyst (DOC) Inspection....4859
Overview....4859
Tools Required....4859
Equipment Condition....4859
Inspection Procedure....4860
Expected Outcome....4860
Selective Catalyst Reduction (SCR) Inspection....4861
Overview....4861
Tools Required....4861
Equipment Condition....4861
Inspection Procedure....4861
Expected Outcome....4862
Follow-On Procedure....4862
Diesel Exhaust Fluid Dosing Unit (DEF: DU) Inspection....4863
Overview....4863
Tools Required....4863
Equipment Condition....4863
Inspection Procedure....4864
Expected Outcome....4865
Decomposition Reactor Tube Inspection....4866
Overview....4866
Tools Required....4866
Equipment Condition....4866
Inspection Procedure....4866
Expected Outcome....4867
Diesel Exhaust Fluid (DEF) Quality Inspection....4868
Overview....4868
Tools Required....4868
Equipment Condition....4868
Inspection Procedure....4868
Expected Outcome....4868
Diesel Exhaust Fluid (DEF) Level & Gauge Inspection....4869
Overview....4869
Tools Required....4869
Equipment Condition....4869
Inspection Procedure....4869
Expected Outcome....4870
Coolant to Oil Sump Inspection ....4871
Overview....4871
Tools Required....4871
Inspection Procedure....4871
Expected Outcome....4871
Oil Pressure Regulator Inspection....4872
Overview....4872
Tools Required....4872
Equipment Condition....4872
Inspection Procedure....4873
Expected Outcome....4873
Cylinder Sleeve Cavitation and Crack Inspection....4874
Overview....4874
Tools Required....4874
Equipment Condition....4874
Inspection Procedure....4874
Expected Outcome....4874
Oil and Crankcase Inspection....4875
Overview....4875
Tools Required....4875
Equipment Condition....4875
Inspection Procedure....4875
Expected Outcome....4877
High-Pressure (HP) Turbocharger Radial Play Inspection....4878
Overview....4878
Tools Required....4878
Equipment Condition....4878
Inspection Procedure....4878
Expected Outcome....4878
Batteries and Electrical System Inspection....4879
Overview....4879
Tools Required....4879
Equipment Condition....4879
Inspection Procedure....4879
Expected Outcome....4879
Aftertreatment....4880
Snap Acceleration Test....4880
Overview....4880
Tools Required....4880
Equipment Condition....4880
Test Setup....4880
Test Procedure....4880
Expected Outcome....4880
Follow-On Procedure....4880
Downstream Injection System Operation Test....4881
Overview....4881
Tools Required....4881
Equipment Condition....4881
Test Setup....4881
Test Procedure....4882
Expected Outcome....4884
Follow-on Procedure....4884
Table of Contents....4885
All Ratings....4887
Engine Specifications....4887
Key-On Engine-Off....4888
Position Sensors....4889
Engine Cranking Specs....4889
Low Idle, No Load, Stabilized Engine Operating Temperature Specs....4889
High Idle, No Load, Stabilized Engine Operating Temperature Specs....4890
Full Load, Rated Speed on Dynamometer, Stabilized Engine Operating Temperature Specs....4890
Engine Coolant Temperatures ECT1, ECT2, Engine Oil Temp, Intake Manifold Temp (IMAT) Specs....4891
Intake Air Temp (IAT) Specs....4891
Diesel Oxidation Catalyst Intake Temp (DOCIT), Diesel Particulate Filter Intake Temp (DPFIT), Diesel Particulate Outlet Temp (DPFOT) Specs....4892
Soot Load Level versus Exhaust Gas Target Temperature Chart....4892
Overview....4892
Soot Load Level versus Exhaust Gas Target Temperature Chart....4892
Other Components Specs....4893
Navistar? 9 (9.3L)....4894
300 hp @ 2000 rpm (12NWC)....4894
315 hp @ 2000 rpm (12NWD)....4896
330 hp @ 2000 rpm (12NWE)....4897
Navistar? 10 (9.3L)....4898
310 hp @ 2000 rpm (12NWG)....4898
330 hp @ 2000 rpm (12NWH)....4900
350 hp @ 2000 rpm (12NWJ)....4901
Fluids....4902
Fluid Specifications and Info....4902
Fuel....4902
Ultra Low Sulfur Diesel (ULSD)....4902
Acceptable Fuel Blends....4902
Use of Higher Biodiesel Fuel Blends (B6 to B20)....4902
Engine Lubrication Oil....4902
SAE Oil Viscosity Grades and Temperature Ranges....4903
Coolant....4904
Cooling System Capacity....4904
Coolant Mixtures....4904
Table of Contents....4905
Electrical Tools....4907
Breakout Harness 18-050-01 (20-way DEF Harness Interconnect)....4907
Breakout Harness 18-650-01 (Ammonia (NH3) Sensor)....4907
Breakout Harness 18-801-01 (Ammonia (NH3) Sensor Module)....4908
Breakout Harness 18-909-01 (DEF Supply Module)....4908
Breakout Harness 18-047-01 DEF Line 3 Heater (Pressure)....4909
Breakout Harness 18-046-01 DEF Line 2 Heater (Return)....4909
Breakout Harness 18-045-01 DEF Line 1 Heater (Supply)....4910
Breakout Harness 18-124-01 (DEF Tank Level and Temperature Sensor)....4910
Breakout Harness 18-649-01 (NOx Out and DOC / DPF Temperature Sensor Module)....4911
Breakout Harness 12-575-01 (DPF Differential Pressure / Outlet Pressure Sensor)....4911
Breakout Harness 18-648-01 (NOx In Sensor Module and SCR Temperature Sensor Module)....4912
Breakout Harness 12-574-01 (8-way DPF Jumper Harness)....4912
Breakout Harness 18-250-01 (12-way SCR Jumper Harness)....4913
Breakout Harness 18-500-01 (12-way AFT Interconnect)....4913
Digital Multimeter (DMM) ZTSE4357....4914
Breakout Harness ZTSE6023 (EFP)....4914
International? Electronic Engine Terminal Test Kit ZTSE4435C....4915
Breakout Harness ZTSE4485A (APP)....4916
Breakout Harness ZTSE4760A (DOCIT, DPFIT, and DPFOT)....4916
Breakout Harness ZTSE4735A (ETV)....4917
Amp Clamp ZTSE4575....4917
3-Banana Plug Harness ZTSE4498....4918
500-Ohm Resistor Harness ZTSE4497....4918
Breakout Harness ZTSE4484 (IPR)....4919
Breakout Harness ZTSE4602 (EOT, ECT1, and AFTFSV)....4919
Breakout Harness ZTSE4674 (ECM and ACT PWR Relays)....4920
Breakout Harness ZTSE4830 (AFTFIS)....4920
Breakout Harness ZTSE4831 (TC2WG)....4921
Breakout Harness ZTSE4834 (EBPV)....4921
Breakout Harness ZTSE4850 (IMP, ICP, EOP, FDP, and EBP)....4922
Breakout Harness ZTSE4908 (EFAN)....4922
Breakout Harness ZTSE4946 (EGT)....4923
Breakout Harness ZTSE4948 (EGR)....4923
Breakout Harness ZTSE4950 (CKP)....4924
Breakout Harness ZTSE4951 (CMP)....4924
Breakout Harness ZTSE4952 (ICP, ECB, and ECBP)....4925
Breakout Harness ZTSE4993 (IMT)....4925
Breakout Harness ZTSE6002 (WIF)....4926
Breakout Harness ZTSE6020 (24-pin)....4926
Breakout Harness ZTSE6021 (AFTFD)....4926
Breakout Harness ZTSE6025 (IAH)....4927
Breakout Harness ZTSE6027 (AFTFP)....4927
Under Valve Cover (UVC) ZTSE4793....4927
DEF Tank Heat Coolant Flow Valve ZTSE4827....4928
Diesel Exhaust Fluid Dosing Unit (DEFDU) ZTSE4828....4928
Mass Air Flow (MAF) Sensor ZTSE4960....4929
Noid Lamp 15-909-01....4929
Mechanical Tools....4930
Radiator Pressure Test Kit ZTSE2384....4930
Pressure Test Kit ZTSE4409....4930
CAC Block Off Kit ZTSE4937....4931
Oil Cooler Test Plate ZTSE4939....4932
Cylinder Head Pressure Test Adapter ZTSE4289A....4933
Thermostat Opening Pressure Test Adapter ZTSE4647....4933
Water Supply Press Test Adapter ZTSE4648....4934
ICP Adapter Pressure Test Fitting ZTSE4927....4934
High Pressure Test Gauge ZTSE4954....4935
Pressure Gauge Adapter 18-538-01....4936
IPR Plug Tester ZTSE4816....4936
Crankcase Pressure Test Tool ZTSE4039....4937
Slack Tube? Manometer ZTSE2217A....4938
Fuel Pressure Gauge ZTSE4681....4939
Fuel Pressure Test Kit ZTSE4657....4940
Charge Air Cooler Test Kit ZTSE4341....4940
EGR Mixing Bowl Guide Pins ZTSE4945....4941
EGR Valve Puller ZTSE4941....4941
Fuel Intake Restriction and Aeration Tool ZTSE6009....4942
Fuel/Oil Pressure Test Coupler ZTSE4526....4942
Fuel Test Fitting ZTSE4692....4943
ICP Test Kit ZTSE4655....4943
Turbo Lifting Bracket ZTSE4942....4944
UV Leak Detection Kit ZTSE4618....4944
Clean Fuel Source Tool 15-637-01....4945
Table of Contents....4947
Engine Component Locator....4949
Aftertreatment Component Locator....4957
Table of Contents....4959
Engine Identification....4963
Engine Serial Number....4963
Engine Serial Number Examples:....4963
Engine Serial Number Codes:....4963
Engine Emission Label....4964
Engine Accessory Labels....4965
Air Management System....4966
Air Flow-Pre Combustion....4967
Air Flow-Post Combustion....4967
Air Management Components....4967
Turbochargers....4967
Interstage Cooler (ISC)....4968
Exhaust Gas Recirculation (EGR) System....4969
The EGR system includes the following: ....4969
Exhaust Gas Recirculation (EGR) Valve....4970
Exhaust Gas Recirculation (EGR) Closed Loop System....4970
Crankcase Ventilation System....4971
Aftertreatment System....4973
Aftertreatment (AFT) System....4973
AFT Control System....4974
DPF....4974
DOC....4974
Selective Catalyst Reduction (SCR) Catalyst ....4974
Decomposition reactor tube ....4974
Sensors....4975
Exhaust Back Pressure Valve (EBPV)....4975
AFT Conditions and Responses ....4975
Diesel Exhaust Fluid (DEF) Injection ....4976
Downstream Injection System ....4977
Fuel Management System....4978
Fuel Management System....4978
Injection Control Pressure (ICP) System....4979
High-Pressure Oil System....4980
Injection Control Pressure (ICP) Closed Loop System ....4980
ICP Control System ....4981
Fuel Injector....4982
Intensifier Piston and Plunger....4983
Plunger and Barrel....4983
Injector Needle....4983
Fuel Injector Operation....4983
Fill Stage ....4984
Injection....4984
End of Injection ....4985
Fuel Supply System....4986
Fuel Supply System Flow ....4987
Intake Air Heater System....4990
Intake Air Heater System....4990
Intake Air Heater (IAH)....4990
Engine Lubrication System....4991
Engine Cooling System....4993
Cooling System Description....4993
Cooling System Components....4994
Coolant Heater (optional)....4994
Thermostat Operation....4994
Electronic Control System ....4997
Electronic Control System Components ....4997
Operation and Function....4997
Doser Control Unit (DCU)....4997
Reference Voltage (VREF)....4997
Microprocessor....4997
Diagnostic Trouble Codes....4997
Microprocessor Memory....4997
Read Only Memory (ROM)....4998
Random Access Memory (RAM)....4998
Actuator Control....4998
ECM Actuators and Sensors....4999
Exhaust Gas Recirculation Valve (EGRV)....5000
Intake Air Heater (IAH) System....5000
Electric Fuel Pump (EFP)....5000
Engine Throttle Valve (ETV) and Engine Throttle Valve Position (ETP) Sensor....5000
Turbocharger 2 Wastegate (TC2WG) position valve....5000
Exhaust Back Pressure Control (EBPC)....5001
Engine Compression Brake Output 1 (ECB1) valve....5001
Injectors....5001
Injection Pressure Regulator (IPR) valve....5001
ACM Actuators....5002
Aftertreatment Fuel Enable Control (AFT: FEC)....5003
Aftertreatment Fuel Pressure Control (AFT: FPC)....5003
Diesel Exhaust Fluid Dosing Unit (DEF: DU)....5003
Diesel Exhaust Fluid Unit Heater Relay (DEF: SMH Relay)....5003
Diesel Exhaust Fluid Line Heater Relay (DEFLHR)....5003
DEF Line 1 Heater Control (DEF: L1HC) Supply Line....5003
DEF Line 2 Heater Control (DEF: L2HC) Return Line....5003
DEF Line 3 Heater Control (DEF: L3HC) Pressure Line....5004
Diesel Exhaust Fluid Tank Heater Control (DEF: THC)....5004
Diesel Exhaust Fluid Supply Module Heater (DEF: SMH)....5004
Diesel Exhaust Fluid Supply Pump (DEF: SP) and DEF Tank Temperature (DEF: TT) Sensors....5004
Diesel Exhaust Fluid Reverting Control Valve (DEF: RCV)....5004
Engine and Vehicle Sensors....5005
Engine Temperature Sensors....5005
Engine Coolant Temperature 1 (ECT1) Sensor....5005
Engine Oil Temperature (EOT) Sensor....5005
Turbocharger 2 Compressor Intake Temperature (TC2CIT) Sensor....5006
Exhaust Gas Temperature (EGT) Sensor....5006
Charge Air Cooler Outlet Temperature (CACOT) Sensor....5006
Intake Air Heater (IAT) Sensor....5006
Intake Manifold Temperature (IMT) Sensor....5006
Ambient Air Temperature (AAT) Sensor....5006
Aftertreatment Temperature Sensors....5007
Diesel Exhaust Fluid Tank Level and Temperature (DEF: TLT) Sensor Module....5007
Diesel Oxidation Catalyst (DOC) / Diesel Particulate Filter (DPF) Temperature Sensor Module....5007
Diesel Oxidation Catalyst Intake Temperature (DOCIT) Sensor....5007
Diesel Particulate Filter Intake Temperature (DPFIT) Sensor....5007
Diesel Particulate Filter Outlet Temperature (DPFOT) Sensor....5007
Selective Catalyst Reduction (SCR) Temperature Sensor Module....5008
Variable Capacitance Sensors....5009
Fuel Delivery Pressure (FDP) sensor....5009
Engine Oil Pressure (EOP) Sensor....5010
Exhaust Back Pressure (EBP) Sensor....5010
Mass Air Flow (MAF) Sensor....5010
Intake Manifold Pressure (IMP) Sensor....5010
Aftertreatment Fuel Pressure 1 (AFT: FP1) sensor....5010
Aftertreatment Fuel Temperature (AFT: FT) sensor....5010
Aftertreatment Fuel Pressure 2 (AFT: FP2) sensor....5010
Diesel Exhaust Fluid Absolute Pressure (DEFAP) sensor....5010
Diesel Particulate Filter Differential Pressure (DPFDP) / DPF Outlet Pressure (DPFOP) sensor....5011
Turbocharger 1 Turbine Outlet Pressure (TC1TOP)....5011
High-pressure Sensors....5012
Brake Control Pressure (BCP) Sensor....5012
Injection Control Pressure (ICP) Sensor....5012
Magnetic Pickup Sensors....5013
Crankshaft Position (CKP) Sensor....5013
Camshaft Position (CMP) Sensor....5013
Vehicle Speed Sensor (VSS)....5013
Crankcase Oil Separator Speed (CCOSS) Sensor....5014
Switches....5015
Driveline Disengagement Switch (DDS)....5015
Engine Coolant Level (ECL) Sensor....5015
Water In Fuel (WIF)....5015
Potentiometer Sensors....5016
Accelerator Pedal Position (APP)....5016
Engine Throttle Valve Control System....5017
Exhaust and Engine Brake System....5018
Exhaust Brake....5018
Engine Brake....5019
Exhaust Back Pressure Control (ECBC)....5019
Engine Compression Brake Output 1 (ECB1)....5020
Brake Pressure Relief Valve....5020
Exhaust Back Pressure (EBP) Sensor....5020
High-pressure Oil Manifold....5020
Operation....5021
Operation Modes....5023
Coast Mode....5023
Latched Mode....5023
Cruise Mode....5023
Chassis Mounted Features....5024
Charge Air Cooler (CAC)....5024
Additional Sensors....5025
Ammonia (NH3) Sensor Module....5025
Nitrogen Oxides (NOx) IN Sensor Module....5025
Nitrogen Oxides (NOx) OUT Sensor Module....5025
Oxygen Sensor (O2S)....5026
Humidity Sensor (HS)....5027
Relays....5028
ECM Power Relay....5029
Actuator Power Relay....5030
Engine Fan Relay....5031
Fuel Pump Relay....5031
Fuel Heater Relay....5032
Starter Relay....5033
Heavy Duty On Board Diagnostics (HD-OBD) Description....5034
Overview....5034
Table of Contents....5035
Standard Electronic Control Features....5037
Aftertreatment (AFT) System....5037
Intake Air Heater....5037
Coolant Temperature Compensation (CTC)....5037
Electronic Speedometer and Tachometer....5037
Engine Crank Inhibit (ECI)....5037
Electronic Governor Control....5037
Event Logging System....5037
Fast Idle Advance....5038
J1939 Datalink....5038
Service Diagnostics....5038
Optional Electronic Control Features....5039
Cruise Control....5039
Engine Brake....5039
Engine Warning Protection System (EWPS)....5039
Idle Shutdown Timer (IST)....5039
IST for California ESS Compliant Engines....5039
Engine Idle Shutdown Timer (IST for Federal ? Optional)....5040
Automatic Engine Speed Control (AESC)....5040
Service Interval....5040
Traction Control....5040
Road Speed Limiter....5040
Table of Contents....5043
Abbreviations and Acronyms....5045
Abbreviations and Acronyms....5045
Table of Contents....5055
Terminology....5057
Terms....5057
tables....2487
Technical Service Literature....2487
Condition / Description....2644
Setting Criteria....2644
Enable Conditions / Condition Values....2644
Condition / Description....2646
Setting Criteria....2646
Enable Conditions / Condition Values....2646
Condition / Description....2648
Setting Criteria....2648
Enable Conditions / Condition Values....2648
Condition / Description....2650
Setting Criteria....2650
Enable Conditions / Values....2650
Condition / Description....2652
Setting Criteria....2652
Enable Conditions / Values....2652
Condition / Description....2654
Setting Criteria....2654
Enable Conditions / Values....2654
Condition / Description....2656
Setting Criteria....2656
Enable Conditions / Values....2656
Condition / Description....2658
Setting Criteria....2658
Enable Conditions / Condition Values....2658
Condition / Description....2660
Setting Criteria....2660
Enable Conditions / Condition Values....2660
Condition / Description....2662
Setting Criteria....2662
Enable Conditions / Condition Values....2662
Condition / Description....2664
Setting Criteria....2664
Enable Conditions / Condition Values....2664
Condition / Description....2668
Setting Criteria....2668
Enable Conditions / Condition Values....2668
Condition / Description....2672
Setting Criteria....2672
Enable Conditions / Condition Values....2672
Condition / Description....2678
Setting Criteria....2678
Enable Conditions / Values....2678
Condition / Description....2681
Setting Criteria....2681
Enable Conditions / Values....2681
Condition / Description....2684
Setting Criteria....2684
Enable Conditions / Values....2684
Condition / Description....2686
Setting Criteria....2686
Enable Conditions / Condition Values....2686
SPN....3232
FMI....3232
Description....3232
Condition / Description....3233
Setting Criteria....3233
Enable Conditions / Values....3233
Condition / Description....3235
Setting Criteria....3235
Enable Conditions / Condition Values....3235
Condition / Description....3237
Setting Criteria....3237
Enable Conditions / Condition Values....3237
Condition / Description....3241
Setting Criteria....3241
Enable Conditions / Condition Values....3241
Condition / Description....3243
Setting Criteria....3243
Enable Conditions / Condition Values....3243
Condition / Description....3245
Setting Criteria....3245
Enable Conditions / Values....3245
Condition / Description....3247
Setting Criteria....3247
Enable Conditions / Values....3247
Condition / Description....3249
Setting Criteria....3249
Enable Conditions / Condition Values....3249
Voltage Check at Relay....3482
Voltage Check at ECM....3482
Harness Resistance Check ? ECM to Relay....3483
Operational Voltage Check....3483
Harness Resistance Check ? Relay to Battery....3483
SPN....4464
FMI....4464
Description....4464
Condition / Description....4465
Setting Criteria....4465
Enable Conditions / Condition Values....4465
SPN....4483
FMI....4483
Description....4483
Condition / Description....4484
Setting Criteria....4484
Enable Conditions / Condition Values....4484
Condition / Description....4488
Setting Criteria....4488
Enable Conditions / Condition Values....4488
Air Management Test Setup....4663
Navistar? 9, and 10 Diesel Engines....4887
Key-On Engine-Off....4888
Key-On Engine-Off....4889
Engine Cranking....4889
Low Idle, no load, stabilized engine operating temperature....4890
Low Idle, no load, stabilized engine operating temperature....4890
High Idle, Parasitic load, at stabilized operating temperature....4890
Crankcase Pressure....4890
Full Load, Rated Speed on Dynamometer, Stabilized Engine Operating Temperature....4890
Engine Component Locations....4955
Component....4955
Location....4955
SCR Switchback Assembly Component Locator Table....4958
Component....4958
Location....4958
0000004021 - N9 and N10 Engine Service Manual....5070
toc....5072
Table of Contents....5072
Safety Terminology....5076
Safety Instructions....5076
Work Area....5076
Safety Equipment....5076
Protective Measures....5076
Vehicle....5076
Engine....5076
Fire Prevention....5076
Batteries....5076
Compressed Air....5077
Tools....5077
Fluids Under Pressure....5077
Fuel....5077
Removal of Tools, Parts, and Equipment....5077
Table of Contents....5078
Engine Identification....5080
Engine Serial Number....5080
Engine Serial Number Examples....5080
Engine Serial Number Codes....5080
Engine Emission Label....5080
Engine Accessory Labels....5080
Engine Description....5081
Standard Features....5082
Optional Features....5083
Optional Cold Climate Features....5083
Chassis Mounted Features....5083
Engine Component Locator....5084
Table of Contents....5092
Engine Preparation....5094
Clean Engine ....5094
Drain Coolant ....5094
Drain Oil ....5094
Removing Engine from Vehicle....5094
Boost Control Harness Assembly and Turbocharger 2 Wastegate Control (TC2WC) Valve ....5094
Turbo Air Inlet Duct Assembly....5094
NOxIN Concentration Sensor and Module assembly....5094
Hydrocarbon Injector Assembly....5094
Throttle Coupling Assembly....5094
Exhaust Brake Valve Assembly....5095
ISC Inlet Duct Assembly....5095
ISC Cooler Assembly....5095
Turbo Oil Supply Assembly....5095
Turbo Wastegate Assembly....5095
Dual Stage Turbo Assembly....5095
Drain High Fin Density EGR Cooler....5095
High Fin Density EGR Cooler Assembly....5095
Oil Filter Removal ....5095
Oil Cooler Removal Assembly....5095
Mounting Engine Stand Bracket and Engine....5095
Mounting Engine Stand Bracket....5095
Table of Contents....5098
Illustrations....5100
Electronic Components ? Top....5100
Electronic Components ? Front....5101
Electronic Components ? Exhaust Side....5102
Electronic Components ? Intake Side....5103
Electronic Components ? Rear....5104
Removal....5105
Boost Control Harness Assembly and Turbocharger 2 Wastegate Control (TC2WC) Valve....5105
Crankshaft Position (CKP) Sensor....5106
Camshaft Position (CMP) Sensor....5106
Exhaust Back Pressure (EBP) Sensor....5107
Engine Control Module (ECM) and Mounting Bracket....5107
Engine Coolant Temperature 1 (ECT1) Sensor....5108
CCOS Sensor....5108
NOxIN Concentration Sensor and Module....5109
Electric Fuel Pump Connector....5109
Fuel Delivery Pressure (FDP) Sensor....5109
Exhaust Gas Recirculation (EGR) Valve Connector....5110
Exhaust Gas Temperature (EGT) Sensor....5110
Engine Oil Pressure (EOP) Sensor....5110
Engine Oil Temperature (EOT) Sensor....5110
Fuel Heater (250 watt)....5111
Intake Air Heater (IAH) Relay Assembly....5111
Injection Control Pressure (ICP) Sensor....5112
Engine Throttle Valve (ETV) Assembly Connector....5112
Injection Pressure Regulator (IPR) Valve Connector....5112
Intake Manifold Pressure (IMP) Sensor....5113
Intake Manifold Temperature (IMT) Sensor....5113
Downstream Injection (DSI) Assembly Connectors....5114
Water In Fuel (WIF) Sensor....5114
Engine Harness Assembly....5115
Valve Cover Gasket Assembly....5117
Inspect....5118
Inspect Wiring Harness, Connectors, and Electrical Components....5118
Installation....5119
Engine Harness Assembly and Camshaft Position (CMP) Sensor....5119
Boost Control Harness Assembly and Turbocharger 2 Wastegate Control (TC2WC) Valve....5122
Crankshaft Position (CKP) Sensor....5122
Exhaust Back Pressure (EBP) Sensor....5122
Electronic Control Module (ECM) and Mounting Bracket....5123
Engine Coolant Temperature 1 (ECT1) Sensor....5123
CCOS Sensor....5124
NOxIN Concentration Sensor and Module ....5124
Fuel Delivery Pressure (FDP) Sensor....5124
Exhaust Gas Recirculation (EGR) Control Valve Connector....5124
Electric Fuel Pump Connector....5125
Exhaust Gas Temperature (EGT) Sensor....5125
Engine Oil Pressure (EOP) Sensor....5126
Engine Oil Temperature (EOT) Sensor....5126
Fuel Heater (250 watt) Connector....5126
Intake Air Heater (IAH) Relay Assembly....5127
Injector Control Pressure (ICP) Sensor....5127
Engine Throttle Valve (ETV) Assembly Connector....5128
Injection Pressure Regulator (IPR) Valve Connector....5128
Intake Manifold Temperature (IMT) Sensor....5128
Intake Manifold Pressure (IMP) Sensor....5129
Downstream Injection (DSI) Assembly Connectors....5129
Water In Fuel (WIF) Sensor....5129
Valve Cover Gasket Assembly....5130
Table of Contents....5132
Exploded Views....5134
Down Stream Injection (DSI) Assembly....5134
Hydrocarbon Injector Assembly....5135
Removal....5136
Down Stream Injection (DSI) Assembly....5136
Injection Unit Inlet Tube Assembly....5137
Hydrocarbon Injector Assembly....5138
Cleaning and Inspection....5140
Hydrocarbon Injector (HCI) / Aftertreatment Fuel Injector (AFI) Cleaning....5140
Exhaust Back Pressure Valve Housing Cleaning....5140
Installation....5141
Hydrocarbon Injector Assembly....5141
Injection Unit Inlet Tube Assembly....5142
Down Stream Injection (DSI) Assembly....5143
Table of Contents....5146
Exploded View....5148
Removal....5153
Interstage Inlet Duct Assembly....5154
Interstage Cooler (ISC)....5157
Throttle Coupling....5159
Turbocharger Oil Supply Tube Assembly....5159
Exhaust Brake Valve and Turbocharger Outlet Elbow....5160
Turbocharger Air Inlet Duct....5162
Turbocharger Wastegate Actuator Assembly....5163
Dual Stage Turbocharger Assembly....5163
High-Pressure Turbocharger Center Section....5164
Cleaning, Inspection, and Testing....5170
Inspect and Clean Dual Stage Turbocharger Assembly and Related Parts....5170
Dual Turbocharger Compressor Cleaning and Inspection....5170
Inspection....5170
Removal of Turbocharger Compressor Covers....5170
Assembly....5172
Inspect Turbine and Compressor....5172
Inspect High-Pressure Turbine Housing....5173
Crossover Tube Seal....5173
Installation....5174
High Pressure Turbocharger Center Section Assembly....5174
Dual Stage Turbocharger Assembly....5180
Turbocharger Wastegate Actuator Assembly (without precise regulated shop air pressure)....5181
Turbocharger Wastegate Actuator Assembly (with precise regulated shop air pressure)....5182
Turbocharger Air Inlet Duct....5183
Exhaust Brake Valve and Turbocharger Outlet Elbow....5183
Turbocharger Oil Supply Tube Assembly....5185
Throttle Coupling....5186
Interstage Cooler (ISC)....5187
Interstage Inlet Duct Assembly....5190
Table of Contents....5194
Exploded View....5196
Removal....5199
Draining High Fin Density EGR Cooler....5199
High Fin Density EGR Cooler and Components....5200
EGR Valve Assembly....5203
Engine Throttle Valve (ETV) Assembly....5203
Air and EGR Mixer Duct Assembly....5203
Cleaning, Inspecting, and Testing....5205
Cleaning and Inspecting EGR System Components....5205
Air and EGR Mixer Duct Assembly....5205
EGR Valve Assembly....5205
Engine Throttle Valve Assembly....5205
High Fin Density EGR Cooler....5205
Pressure Testing High Fin Density EGR Cooler....5205
EGR Cooler Vent Tool....5206
EGR Cooler Coolant Port Tool....5206
EGR Cooler Exhaust Inlet Tool....5206
EGR Cooler Exhaust Outlet Tool....5206
SAE J512 Plugs....5207
EGR Cooler Leak Test....5207
Installation....5208
Air and EGR Mixer Duct Assembly....5208
Engine Throttle Valve (ETV) Assembly....5209
EGR Valve Assembly....5209
High Fin Density EGR Cooler and Components....5210
Table of Contents....5214
Exploded View....5216
Removal....5218
Exhaust Manifold....5219
Intake Manifold, Fuel Valve, and Fuel Rail Plugs....5220
Cleaning, Inspection, and Measurements....5223
Exhaust Manifold....5223
Exhaust Back Pressure (EBP) Sensor Tube Assembly....5223
Intake Manifold....5223
Installation....5224
Exhaust Manifold....5224
Intake Manifold, Fuel Valve, and Fuel Rail Plugs....5226
Table of Contents....5230
Exploded Views....5232
Periodic Service....5236
Fuel Strainer....5236
Fuel Filter....5237
Draining Water From Fuel Filter Assembly....5237
Removal....5238
Water In Fuel (WIF) Sensor, Fuel Delivery Pressure (FDP) Sensor, and 250 Watt Fuel Heater....5238
Water Drain Valve Assembly....5238
Brushless Electric Fuel Pump Assembly....5239
Fuel Pressure Regulator Valve Assembly....5239
Fuel Filter Assembly....5241
High-pressure Oil Hose and Elbows....5242
High-pressure Oil Pump Assembly and Injection Pressure Regulator (IPR) Valve Assembly....5243
High-pressure Oil Manifold....5245
Injector Oil Inlet Adapter (Puck) Assembly....5246
Fuel Injector Assemblies....5247
Cleaning and Inspection....5248
Fuel Filter Assembly Service Recommendations....5248
High-pressure Oil System Components....5248
Installation....5250
Fuel Injector Assemblies....5250
Injector Oil Inlet Adapter (Puck) Assembly....5251
High-pressure Oil Manifold....5251
High-pressure Oil Pump Assembly and Injection Pressure Regulator (IPR) Valve Assembly....5253
High-pressure Oil Hose and Elbows....5255
Fuel Filter Assembly....5257
Water Drain Valve Assembly....5258
Brushless Electric Fuel Pump Assembly and Fuel Strainer....5258
Fuel Pressure Regulator Valve Assembly....5259
Water In Fuel (WIF) Sensor, Fuel Delivery Pressure (FDP) Sensor, and 250 Watt Fuel Heater....5259
Table of Contents....5262
Exploded View and Description....5264
High-pressure Oil Manifold (Brake)....5264
Periodic Service....5265
Engine Brake Lash Adjustment....5265
Removal....5268
Engine Compression Brake (ECB) Valve....5268
Engine Compression Brake Pressure (ECBP) Sensor....5268
Valve Cover Gasket (Harness) Assembly (Brake)....5269
High-pressure Oil Manifold (Brake)....5270
Oil Pressure Relief Valve....5271
Brake Actuator Piston Assembly....5271
Cleaning and Inspection....5273
Installation....5274
Brake Actuator Piston Assembly....5274
Oil Pressure Relief Valve....5274
High-pressure Oil Manifold (Brake)....5275
Valve Cover Gasket (Harness) Assembly (Brake)....5277
Engine Compression Brake Pressure (ECBP) Sensor....5277
Engine Compression Brake (ECB) valve assembly....5278
Table of Contents....5280
Illustrations....5282
Air Compressor....5282
Power Steering Pump....5283
Description....5284
Air Compressor....5284
Power Steering Pump....5284
Removal....5284
Power Steering Pump....5285
Air Compressor....5286
Cleaning and Inspection....5287
Installation....5288
Air Compressor....5288
Power Steering Pump Without Air Compressor....5289
Power Steering Pump With Air Compressor....5289
Table of Contents....5290
Exploded View and Description....5292
Removal....5293
Drain Coolant....5293
Oil Cooler Module....5295
Disassemble....5296
Pressure Regulator Valve (Oil)....5296
Thermal Valve (Oil)....5296
Oil Cooler....5297
Cleaning, Inspection, and Testing....5298
Clean Oil Cooler Housing....5298
Oil Cooler Pressure Test....5300
Assemble....5301
Oil Cooler....5301
Thermal Valve (Oil)....5302
Regulator Valve (Oil)....5303
Installation....5303
Oil Cooler Module....5303
Oil Filter....5305
Prime Lubrication System....5305
Priming System....5305
Cranking Method (Alternate)....5306
Table of Contents....5308
Exploded Views....5310
Front Sump....5310
Rear Sump....5311
Removal....5312
Drain Engine Oil....5312
Oil Pan and Gasket....5312
Suction Tube Assembly....5313
Cleaning and Inspecting....5314
Oil Pan and Suction Tube....5314
Installation....5315
Suction Tube Assembly....5315
Oil Pan and Gasket....5316
Fill Engine with Oil....5317
Table of Contents....5320
Exploded View....5322
Removal....5324
Dual Drive Belt....5324
Single Drive Belt....5325
Dual Idler Pulleys....5326
Alternator Support....5327
Secondary Compressor Support, Flat Idler Pulleys, and Idler Support Plate....5328
Coolant Supply Housing (Refrigerant Compressor Mount)....5329
Water Outlet Tube and Thermostat....5329
Water Pump Assembly....5330
Water Inlet Elbow....5330
Fan Drive....5331
Spin-on Fan Drive....5331
Horton DriveMaster? Fan Drive....5332
Vibration Damper, Hub, and Wear Sleeve....5333
Vibration Damper?Single Drive Belt Engines....5333
Vibration Damper?Dual Drive Belt Engines....5333
Damper Hub....5334
Oil Pump Assembly....5335
Front Engine Mount....5336
Front Cover (Front Half)....5337
Idler Gears....5338
Front Cover (Rear Half)....5340
Cleaning, Inspection, and Measurement....5341
Cleaning and Inspection....5341
Measuring Gear Backlash....5341
Lower Idler Gear Backlash....5341
Upper Idler Gear Backlash....5342
Camshaft Gear Backlash....5342
Measuring Oil Pump Side Clearance....5343
Measuring Oil Pump End Clearance....5343
Installation....5344
Front Cover (Rear Half)....5344
Idler Gears....5346
Front Cover (Front Half)....5348
Front Engine Mount....5350
Oil Pump Assembly....5350
Vibration Damper, Hub, and Wear Sleeve....5353
Damper Hub....5353
Vibration Damper?Dual Drive Belt Engines....5355
Vibration Damper?Single Drive Belt Engines....5356
Fan Drive....5356
Spin-on Fan Drive....5356
Horton DriveMaster? Fan Drive....5358
Water Outlet Tube and Thermostat....5359
Water Pump Assembly....5359
Water Inlet Elbow....5360
Coolant Housing (Refrigerant Compressor Mount)....5360
Alternator Support....5362
Dual Idler Pulleys....5363
Secondary Compressor Support, Flat Idler Pulleys, and Idler Support Plate....5364
Single Drive Belt....5366
Dual Drive Belt....5367
Table of Contents....5370
Illustrations and Description....5372
Exploded View of Cylinder Head and Valve Train Components....5372
Description....5373
Periodic Service....5374
Valve Lash Adjustment....5374
Removal....5378
Valve Cover....5378
Rocker Arm Assembly....5380
Rocker Arms....5381
Cylinder Head....5381
Roller Tappets and Guides....5382
Cleaning, Inspection, Measurement, and Testing....5383
Measuring Camshaft Lobe Lift....5383
Cylinder Head Cleaning....5383
Cleaning and Inspection of Roller Tappets and Guides....5384
Cleaning and Inspection of Push Rods....5384
Measuring Rocker Shaft....5384
Inspection and Measurement of Rocker Arms....5385
Measuring Cylinder Head Warpage....5386
Measuring Cylinder Head Thickness....5387
Measuring Valve Seat Leakage....5387
Inspecting Cylinder Head for Cracks....5387
Cylinder Head Pressure Test....5388
Reconditioning....5390
Removal of Valves from Cylinder Head....5390
Inspection and Measurement of Valve Guides....5390
Replacing Valve Guides....5392
Inspecting and Measurement of Valve....5393
Refacing Valves....5394
Valve Face....5394
Refacing Valve Stem Tip....5395
Valve Face-to-Seat Contact Inspection....5395
Resurfacing Valve Seats....5396
Replacing Valve Seats....5397
Removal....5397
Installation....5399
Valve Spring Inspection....5400
Inspecting Valve Rotators and Retainers....5402
Inspecting Valve Spring Retainer Keys....5402
Replacing Fuel Injector Sleeves....5403
Removal....5403
Tool Removal....5405
Cleaning....5405
Installation....5405
Installing Valves....5407
Cleaning....5407
Assembly....5407
Installation....5408
Roller Tappets and Guides....5408
Cylinder Head....5408
Torque Procedure for Torque-to-yield Head Bolts....5410
Rocker Arms....5412
Rocker Arm Assembly....5413
Valve Cover....5415
Table of Contents....5420
Exploded View and Description....5422
Flywheel housing SAE 1....5423
Flywheel housing SAE 1A....5423
Flywheel housing SAE 2....5423
Flywheel housing (Bus) SAE 2....5423
Flywheel and Flexplate Applications....5423
Manual Transmissions....5423
Automatic Transmissions....5425
Removal....5427
Flywheel Assembly....5427
Flexplate (Automatic Transmissions)....5428
Allison 2000 Series Transmissions....5429
MD-3000 Series Transmissions....5429
Crankshaft Timing Disk....5430
Rear Oil Seal Assembly....5431
Flywheel Housing....5432
Cleaning, Inspection, and Measurement....5434
Clean and Inspect....5434
Measurement of Flywheel Housing Face Runout....5434
Measurement of Flywheel Housing Bore Concentricity....5435
Measurement of Crankshaft Pilot Concentricity....5435
Measurement of Flywheel Surface Runout....5436
Recondition....5437
Resurface Flywheel....5437
Replacement of Flywheel Ring Gear....5437
Installation....5438
Flywheel Housing and Rear Engine Mounting Brackets....5438
Rear Oil Seal....5440
Crankshaft Timing Disk....5441
Flywheel Assembly....5442
Flexplate (Automatic Transmissions)....5443
Allison 2000 Series Transmissions....5443
MD-3000 Series World Transmissions....5444
Table of Contents....5446
Exploded View and Description....5448
Removal....5449
Piston Cooling Tubes....5449
Piston Protrusion Measurement ? Preliminary Check....5449
Piston and Connecting Rod Assembly....5450
Piston Pin and Rings....5452
Cylinder Sleeve....5453
Cleaning, Inspecting, and Measuring....5454
Cleaning and Inspecting....5454
Measuring Pistons....5455
Top Compression Ring Grooves....5455
Intermediate and Oil Control Ring Groove....5456
Piston-to-Cylinder Sleeve Running Clearance....5456
Measuring Piston Rings....5457
Measuring Piston Pins....5457
Measuring and Inspecting Connecting Rods....5458
Piston Pin Bushing....5458
Connecting Rod Bolt Holes Inspection....5458
Connecting Rod Bearing Bore (Big End)....5459
Connecting Rod Bend and Twist....5459
Bearing Fitting Procedures....5460
Measuring Bearing Running Clearance....5460
Measuring Connecting Rod Side Clearance....5461
Measuring Cylinder Sleeves....5462
Telescoping Gauge Method....5462
Dial Bore Gauge Method....5463
Feeler Gauge Method....5463
Measuring Counterbore Depth....5464
Cylinder Liner Height Gauge Method....5464
Depth Micrometer Method....5464
Measuring Cylinder Sleeve Protrusion....5465
Reconditioning....5467
Resurfacing Counterbore....5467
Preparation....5467
Mounting the Counterbore Reconditioning Tool....5468
Tool Settings....5469
Cutting Counterbore Ledge....5470
Tool Care and Maintenance....5471
Installation....5472
Cylinder Sleeve....5472
Piston Rings....5473
Piston Pin....5474
Piston and Connecting Rod Assembly....5475
Torque-to-yield Procedure for Connecting Rods....5477
Piston Cooling Tubes....5478
Engine Run-in Procedure....5479
Table of Contents....5484
Exploded Views and Description....5486
Centrifuge Oil Filter....5486
Crankcase Breather Assembly with Turbine....5487
Crankcase, Crankshaft, and Camshaft....5488
Removal....5490
Centrifuge Oil Filter....5490
Crankcase Ventilation System....5491
Oil Level Gauge Assembly....5494
Coolant Heater Assembly (optional)....5494
Crankcase Ladder Assembly....5494
Camshaft Gear....5495
Camshaft Assembly....5496
Camshaft Bearings....5497
Main Bearing Caps, Crankshaft, and Main Bearings....5499
Oil Pump Spline Drive and Crankshaft Gear....5500
Cleaning, Inspection, and Measurement....5501
Camshaft Assembly....5501
Centrifuge Oil Filter Cleaning and Inspection....5501
Crankcase Breather Assembly....5502
Crankcase, Cup Plugs, and Piston Cooling Tubes....5502
Crankshaft and Main Bearings....5503
Camshaft End Play Measurement....5504
Camshaft Lobes and Journals Measurement....5504
Crankshaft End Play Measurement....5505
Installation....5506
Camshaft Bearings....5506
Camshaft Assembly....5509
Camshaft Gear....5509
Crankshaft Gear and Oil Pump Spline Drive....5510
Upper Main Bearings and Crankshaft Assembly....5511
Main Bearing Fit Procedure....5513
Main Bearings and Caps....5515
Torque Procedure for Torque-to-yield Main Bearing Cap Bolts....5516
Crankcase Ladder Assembly....5517
Coolant Heater Assembly (optional)....5518
Oil Level Gauge Assembly....5519
Crankcase Ventilation System....5520
Centrifuge Oil Filter....5522
Table of Contents....5524
Abbreviations and Acronyms....5526
Abbreviations and Acronyms....5526
Table of Contents....5532
Terminology....5534
Terms....5534
Table of Contents....5544
Specifications....5546
Fuel and High-Pressure Oil Systems....5546
Engine Brake....5546
Air Compressor and Power Steering Pump....5546
Oil System Module Assembly....5546
Oil Pan and Oil Suction Tube....5546
Front Cover, Cooling System, and Related Components....5547
Cylinder Head and Valve Train....5549
Flywheel and Flywheel Housing....5551
Power Cylinders....5552
Crankcase, Crankshaft, and Camshaft....5555
Table of Contents....5560
General Torque....5562
Bolt Identification....5562
General Torque Guidelines....5563
Standard Torque Charts....5564
Using a Torque Wrench Extension....5565
Special Torque....5566
Mounting Engine on Engine Stand....5566
Engine Electrical....5566
Down Stream Injection (DSI) & Related Components....5566
Dual Stage Turbocharger and Exhaust Brake....5567
Exhaust Gas Recirculation (EGR) System....5567
Intake, Inlet and Exhaust Manifolds....5567
Fuel and High-pressure Oil Systems....5568
Engine Brake....5569
Air Compressor and Power Steering Pump....5569
Oil System Module Assembly....5570
Oil Pan and Oil Suction Tube....5570
Front Cover, Cooling System, and Related Components....5570
Cylinder Head and Valve Train....5571
Flywheel and Flywheel Housing....5571
Power Cylinders....5571
Crankcase, Crankshaft, and Camshaft....5571
Table of Contents....5572
Tool Ordering Information....5574
Special Tools....5574
Mounting Engine on Engine Stand....5574
Dual Stage Turbocharger and Exhaust Brake....5574
Exhaust Gas Recirculation (EGR) System....5574
Intake, Inlet and Exhaust Manifolds....5575
Fuel and High-pressure Oil Systems....5575
Engine Brake....5575
Oil System Module Assembly....5575
Oil Pan and Oil Suction Tube....5575
Front Cover, Cooling System, and Related Components....5576
Cylinder Head and Valve Train....5576
Flywheel and Flywheel Housing....5577
Power Cylinders....5578
Crankcase, Crankshaft, and Camshaft....5578
Photos of Essential Tools....5579
tables....5081
N9 and N10 Diesel Engines....5081
Engine Component Locations....5088
Component....5088
Location....5088
Valve Seat Insert Selection Chart....5399
Piston Ring Gauge Pin Selection....5455
Water Pump Pulley Diameters and Spin Ratios....5547
Fan Drive Configurations Diameters and Ratios (DriveMaster?) ? Dual Drive Belt....5548
Valve Specifications....5549
Valve Spring Specifications....5550
Cylinder Head and Valve Train Specifications....5550
Flywheel Housing....5551
Crankshaft Pilot....5552
Flywheel....5552
Flywheel Resurfacing Specifications....5552
Connecting Rod Specifications....5552
Piston Specifications ? N9 and N10....5553
Piston Ring Specifications (in 116.573 mm diameter gage ring)....5553
Piston Pin Specifications....5553
Cylinder Sleeve Specifications....5554
Crankcase Specifications ....5555
Camshaft Specifications ....5556
Camshaft Bearing Specifications....5556
Crankshaft Specifications....5557
Crankshaft Specifications (continued)....5558
Standard Torque Values - Class 10.9 Metric Flange Head Bolts and Studs....5564
4328224R1 - N9 and N10 Engine Operation and Maintenance Manual....5585
toc....5593
About the Manual....5593
Safety Terminology....5595
Safety Instructions....5595
Work Area....5595
Safety Equipment....5595
Protective Measures....5595
Vehicle....5596
Engine....5596
Fire Prevention....5596
Batteries....5596
Compressed Air....5596
Tools....5597
Fluids Under Pressure....5597
Fuel....5597
Removal of Tools, Parts, and Equipment....5597
Federal Emission System Warranty....5599
Warranty Period....5599
Required Maintenance....5599
Warranty Repairs and Service....5599
Recommended Maintenance or Repair Parts....5599
Emergency Repairs....5600
What is not Covered by Warranty....5600
Unauthorized parts or expendable parts....5600
Vehicle, engine, and part malfunctions caused by the following:....5600
Conditions not covered by Warranty....5600
Warranty Rights and Responsibilities....5601
California Emission System Warranty....5601
Warranty Period....5601
Required Maintenance....5601
Warranty Repairs and Service....5602
Recommended Maintenance or Repair Parts....5602
Emergency Repairs....5602
What is Covered by Warranty....5602
What is not Covered by Warranty....5603
Unauthorized parts or expendable parts:....5603
Vehicle, engine, and part malfunctions caused by the following:....5604
Conditions not Covered by Warranty:....5604
Warranty Rights and Responsibilities....5604
Engine Serial Number....5605
Engine Serial Number Examples....5605
Engine Serial Number Codes....5605
Engine Emission Label....5606
Engine Accessory Labels and Identification Plates....5606
Engine Specifications....5607
Engine Description....5608
Engine Features....5610
Engine Optional Features....5612
Power Take Off (PTO)....5613
Engine Component Locations....5615
Component Location - Top....5615
Component Location - Front....5616
Component Location - Intake Side....5617
Component Location - Exhaust Side....5618
Component Location - Rear....5619
Fuel....5621
Ultra Low Sulfur Diesel (ULSD) ....5621
Unacceptable Fuel and Blends....5621
Acceptable Fuel Blends....5622
Use of Higher Biodiesel Fuel Blends (B6 to B20)....5622
Unsafe Practices....5623
Engine Oil....5623
Engine Oil Quality and Service Categories....5623
API CJ-4 for High Performance Diesel Engines....5623
SAE Oil Viscosity Grades And Temperature Ranges....5624
Coolant....5625
Coolant Mixtures....5625
Extended Life Coolant (ELC) ? Red....5625
Contamination of Coolant....5626
Instrument Panel Gauge Cluster....5627
Warning Lights....5627
Wait to Start Lamp....5627
Idle Shut Down Indicator....5627
Maintenance Lamp....5628
Amber Warning Lamp (AWL)....5628
RED Stop Lamp (RSL)....5628
High Exhaust System Temperature (HEST) Lamp....5629
Diesel Exhaust Fluid (DEF) Low Level Lamp....5629
Diesel Particulate Filter (DPF) Indicator....5629
Level One....5630
Malfunction Indicator Lamp (MIL)....5630
Typical Water Temperature Gauge....5631
Diesel Exhaust Fluid (DEF) Level Gauge....5631
tables....5607
Navistar? N9 and N10 Engines....5607
?Low idle....5607
Navistar? N9 and N10 Engines....5608
Freeze Point Protection Levels Concentrate (ethylene glycol) and Water Mixtures....5625
N9 N10 (4328224)_48-102.pdf....0
toc....5632
Oil Pressure Gauge....5632
Oil Temperature Gauge....5633
Switches....5634
Engine Brake ON / OFF Switch....5634
Engine Exhaust Brake ON / OFF Toggle Switch....5634
Air Cleaner Restriction Indicator....5635
Air Restriction Indicator Calibration....5635
Air Restriction Indicator Operation....5635
Air Restriction Indicator Reset....5635
tables....5632
Lubrication Oil Pressure....5632
Navistar? N9 and N10 Engines....5651
Navistar? N9 and N10 Engine ....5659
Freeze Point Protection Levels Concentrate (ethylene glycol) and Water Mixtures....5667
ELC Extender....5675
Maintenance Service Record....5684
Maintenance Service Record....5685
toc....5637
Preoperation Checklist....5637
Priming the Fuel System....5638
Starting the Engine....5638
Emergency Starting....5640
Operation....5641
Suggested Warm up Time....5641
Idle Speed....5641
Extended Idling Periods....5641
Exhaust Aftertreatment System....5642
Aftertreatment (AFT) High-soot auto engine shut down....5642
Selective Catalytic Reduction (SCR) System (If Equipped)....5643
Engine Idle Shutdown Timer (Federal-Optional)....5644
Engine Idle Shutdown Timer (California-Standard)....5645
Cold Weather Operation....5646
Cold Ambient Protection (CAP)....5647
Hot Weather Operation....5647
Engine Shutdown....5648
HD-OBD Overview ....5648
Radiator Shuttle Enable (RSE)....5648
Road Speed Limiting (RSL)....5648
Road Operation....5648
Downhill Operation....5649
Maintenance Schedule....5651
Service Procedures....5654
Oil Level....5654
Coolant Level....5655
Water Separator ....5656
Charge Air Cooler (CAC)....5657
External Leakage....5657
Air Cleaner Restriction ....5658
Engine Oil and Filter....5658
Engine Oil Sampling - Optional....5659
Centrifuge Filter (If Equipped)....5662
Resetting Change Engine Oil Service Interval Message....5665
Belt, Air Intake Piping and Clamps....5665
Coolant Freeze Point....5667
Fuel Filter....5668
Fuel Strainer....5671
Electrical System....5673
Vibration Damper....5674
Engine Valve Lash....5674
Engine Brake Lash....5674
Induction System....5674
Extended Life Coolant (ELC) Extender....5675
Crankcase Pressure....5676
Turbochargers....5676
Cleaning Diesel Particulate Filter....5676
Service Cooling System....5677
General Information....5681
Maintenance Service Record....5683
Daily Care and Report....5686
